PT PLN (PERSERO) CILEGON COMBINED CYCLE POWER PLANT (740MW) CONTRACT NO.:0136.PJ/060/DIR/2004 OPERATION MANUAL (ST HRSG BOP PART) MECHANICAL VOLUME-12 NJ-05036 R-1 CONTRACTOR : MITSUBISHI CORPORATION MITSUBISHI HEAVY INDUSTRIES, LTD. MITSUBISHI ELECTRIC CORPORATIONRECORD OF CHANGES DOCUMENT NUMBER: NJ-05036, JHRSG/BOP -Part including the responses to Customer's comments. Revision Date Title and Brief Description Remarks. | Entered No. by — | 2006/02/14 | Issued Design Manual, Operation Manual & Maintenance Manual for Steam Turbine/HRSG/BOP Part. 1 2006/08/11 | Fully revised Steam Turbineaf PUTSUBISHI IMPORTANT INFORMATION © These documents are intended for the use by operating and maintenance personnel and must be accessible to them at ail times. © Do not perform any operation or maintenance on this system until you read and understand all instructions in these documents. © You must comply with all applicable laws, codes and local regulation. © Only qualified personnel must work on or around this system after becoming thoroughly familiar with all warnings, safety notices, operating procedures, and maintenance procedures contained herein. © Employers must implement all training and safety requirements mandated by national standards and local governing agencies.” © Mitsubishi Heavy Industries, Ltd. (herein after referred to as MHI) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in these documents and on the equipment are therefore not alt inclusive. © Improper operation or maintenance of this system can be dangerous and could result in injury or death. © Ifa procedure, work method or operating technique not specified in this manual is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the system will not be damaged or made unsafe by the method of operation or maintenance procedure you choose. © Itis assumed that this system will be operated and serviced by English speaking personnel. If this is not the case, the customer should add safety, caution, and operating signs in the native language of the operating and maintenance personnel. © Should particular problems arise which are not covered sufficiently for the intended purposes in these documents, you should refer to following: Mitsubishi Heavy Industries, Ltd. ‘Takasago Machinery Works 4-1,Arai-cho, Shinhama 2-chome, Takasago City,Hyogo, Japan 676-8686, © These documents are placed at your disposal for your own use only and may not be copied, nor reproduced in hard copy or any electric medium. The copyright remains with MHI. ‘MHI Proprietary Information i—_— Airc LIMITED WARRANTY The warranty contained in the Contract between the patties is the sole warranty of MHI. Any statements contained herein do not create new warranties or modify the existing warranty. MHI DOES NOTWARRANT AND IS NOT RESPONSIBLE FOR: © DAMAGE CAUSED BY FAILURE TO PROVIDE A SUITABLE OPERATING ENVIRONMENT FORTHE SYSTEM; © DAMAGE CAUSED BY FOREIGN OBJECTS, DROPPING, FALL, SPILLED LIQUIDS, OR IMMERSION IN LIQUIDS OR GASES; © DAMAGE CAUSED BY A POWER SURGE OR IMPROPER SUPPLIED UTILITY; © DAMAGE CAUSED BY ATTACHMENTS, ALTERATIONS, OR MODIFICATIONS VWUTHOUT MHIS WRITTEN APPROVAL; © DAMAGE FROM IMPROPER OPERATION OR MAINTENANCE; © DAMAGE CAUSED BY ANY ABUSE, MISUSE, MISHANDLING, OR MISAPPLICATIONS; © PRODUCTS OR SERVICES OF COMPANY OTHER THAN MHI OR MHI AUTHORIZED ‘COMPANY. © DAMAGE CAUSED BY UNSPECIFIED UTILITY CONDITIONS SUCH AS TEMPERATURE, PRESSURE, FLOW RATE, CONCENTRATION AND QUALITY; ‘© DAMAGE CAUSED BY ANY BUGS IN THE MEMORY CHIPS OR OPERATING SOFTWARE OTHER THAN MHI'S SOFTWARE; ‘MI Proprietary information iife TSU SAFETY INSTRUCTION General Safety Rules © This system contains hazardous voltage, rotating parts, high pressure, high temperature, chemical and noise. © During operation and maintenance, extreme caution must be exercised for personnel to be in proximity of potentially dangerous mechanical and electrical devices. © Never operate any equipment unless all guards and safety devices are in place and in proper operating conditions. , © Keep the area well maintained at all times. © Most accidents involving system operation and maintenance are caused by failure to observe basic safety rules or precautions. © Wear appropriate work clothes, gloves, shoes or boots, hard hats and eye protectors in accordance with customer's Personal Protective Equipment Program. © Incase of an accident while running, shut down the system immediately if required. © MSDS (Material Safety Data Sheets) should be filed for easy access, and safety & handling instruction should be followed. ©. Operate the system in accordance with customer's Health and Safety programs. oO Make reports for any improper operation, misoperation of system, especially safety devices and repair records. Return tools to their proper places after use. Warn others of an intended action that may endanger them. Do not remove safety devices. Do not start the system unless you are sure there is no danger to you and others. ocoo00o 0 Do not leave unattended equipment in an unsafe condition. ‘MHI Proprietary Information ifa MITSUBISHI © General Safety Rules (Cont.) in these documents and on the product, DANGER indicates immediate danger and that special precautions are necessary. CAUTION indicates warning against potential hazards or caution against unsafe practices. ‘MHI Proprietary information ivINDONESIA PLN CILEGON C/C OPERATI ST HRSG BOP PART IMPORTANT INFORMATION LIMITED WARRANTY SAFETY INSTRUCTIONS. SECTION 1 SECTION 2 SECTION 3 SECTION 4 GENERAL POWER PLANT MECHANICAL ELECTRICAL Short Contents iiiVOLUME SECTION 1 1 44 24 22 23 2.3.1 2.3.2 2.3.3 24 241 242 25 2.56.1 2.5.2 2.5.2.1 25.22 25.2.3 2.5.2.4 25.2.5 25.26 25.2.7 2.5.28 2.53 DESCRIPTION GENERAL GENERAL INFORMATION ON OPERATION POWER PLANT OPERATING PROCEDURE PRINCIPAL OPERATING LIMITS REQUIRED ACTION AT EMERGENCY GENERAL STEAM TURBINE BOTTOMING CYCLE CONTROL SETTING (INCLUDING ALARM & TRIP SET POINTS) STEAM TURBINE RELATED EQUIPMENT BOTTOMING CYCLE HRSG OPERATION FUNCTIONAL DESCRIPTION OF CONTROL OPERATION GUIDELINES: GUIDELINES FOR HRSG START-UP OPERATION PREDICTED START-UP AND SHUT-DOWN PERFORMANCE GUIDELINES OF HRSG CONTROL, HRSG PREDICTED PERFORMANCE GENERAL PRECAUTION PRECAUTION DURING OPERATION BLOW-OFF PROCEDURE PRESERVATION PROCEDURE CONTROL SETTING (INCLUDING ALARM & TRIP SET POINTS) Contents PAGES 44-4 21-1 22-1 23-4 23-3 2.3-47 24-1 24-3 25-1 2.5-35 2.5-37 2.542 2.6-43 2.5-44 2.5-46 25-49 2.5-50 25-51Contents VOLUME SECTION DESCRIPTION PAGES: 3 3 MECHANICAL: 3.4 OIL SYSTEM 3.4.41 CONTROL AND LUBE OIL SYSTEM 34-4 3.2 CONDENSATE WATER SYSTEM 3.2.1 CONDENSATE PUMP 3.2-1 3.2.2 CONDENSER VACUUM PUMP 3.2-39 3.2.3 MAKE UP WATER PUMP. 3.2-101 33 FEED WATER SYSTEM 3.3.1 HPAP FEED WATER PUMP 33-1 3.3.2 LP FEED WATER PUMP. 3.3-331 4 3.4 CIRCULATING WATER SYSTEM 3.4.1 CIRCULATING WATER PUMP. 34-4 34.2 CWP LUBE WATER PUMP: 3.4-169 3.4.3 SEA WATER BOOSTER PUMP 3.4-221 3.44 CONDENSER TUBE CLEANING SYSTEM 3.4-289 3.4.5 CONDENSER DEBRIS FILTER 3.4-323 3.4.6 CW PRIMING PUMP 3.4-547 35 ST CLOSED COOLING WATER SYSTEM 3.5.4 ST CLOSED COOLING WATER PUMP: 3.5-1 5 3.6 MAIN CYCLE CHEMICAL INJECTION SYSTEM 3.6-1 37 SAMPLING SYSTEM & CONDENSER TUBE LEAK 37-1 DETECTOR 6 38 FUEL GAS TREATMENT PLANT 3.81 3.9 HSD FUEL-OIL UNLOADING STATION 3.9-4 3.10 DESALINATION PLANT 3.10-4 7 3.11 DEMINERALIZED WATER SYSTEM 3.11.4 DEMINERALIZED WATER SYSTEM 311-1 3.11.2. DEMINERALIZED WATER TRANSFER PUMP. 3.11-2 3.12 SERVICE WATER SYSTEM 3.12.1 SERVICE WATER PUMP 3.12-4 3.13, INSTRUMENT AND SERVICE AIR SYSTEM 3.13.1 INSTRUMENT AND SERVICE AIR COMPRESSOR 313-1 3.13.2 INSTRUMENT AIR DRYER: 3.13-185) 8 3.14 FIRE FIGHTING SYSTEM 314-1 9 3.15 NITROGEN STORAGE AND DISTRIBUTION SYSTEM —3.15-1 3.16 HYDROGEN PLANT 3.16-1 3.17 STANDBY DIESEL ENGINE GENERATOR S.A7-1 3.18 HVAC SYSTEM 3,18-1 viiVOLUME 9(Cont) 10,14 12 SECTION 3.19 3.20 3.21 3.214 3.21.2 3.21.3 3.22 3.23 3.23.1 3.23.2 3.24 3.25 3.26 Contents DESCRIPTION PAGES: WASTE WATER TREATMENT SYSTEM 3.19-1 AUXILIARY BOILER 3.20-1 SCREEN SYSTEM STOP LOG & STORAGE 3.21-1 BAR SCREEN & TRAVELING TRASH RAKE 3.21-27 TRAVELING BAND SCREEN & WASH WATER DEVICE 3.21-105 CHLORINATION SYSTEM 3.22-1 CATHODIC PROTECTION SYSTEM CATHODIC PROTECTION SYSTEM FOR FIELD PIPING 3.23- 1 CATHODIC PROTECTION SYSTEM FOR CIRCULATING 3.23-15 WATER SYSTEM POTABLE WATER CHEMICAL INJECTION SYSTEM 3.24-41 HSD FUEL OIL TREATMENT SYSTEM 3.25-1 SUMP PUMP: 3.26-1 ELECTRICAL GENERATOR GENERATOR AND GENERATOR AUXILIARY (STG) PT & SA CUBICLE CONTROL PANEL SYSTEM DESCRIPTION EXCITATION CONTROL PANEL (EXC, AVR) GENERATOR CONTROL PANEL GENERATOR PROTECTION RELAY PANEL TRANSFORMER PROTECTION RELAY PANEL SEAL OIL CONTROL PANEL TRANSFORMER ST GENERATOR TRANSFORMER LV TRANSFORMER ISOLATED PHASE BUSDUCT NIA 6.3KV MV SWITCHGEAR MC SET-INSTRUCTIONS FOR USE LF DRAW-OUT CIRCUIT BREAKERS-INSTRUCTIONS FOR USEAMeont) 4.7.3 474 475 48 4.8.1 4.8.2 49 4.9.1 4.9.2 4.10 18 4.11 4.12 4.13 4.14 415 19 4.16 417 4.18 20,21,22 4.19 VOLUME SECTION DESCRIPTION MC SET METAL CLAD SWITCHGEAR-CATALOGUE 2003 SEPAM-PROTETION RELAY FOR MC SET METAL CLAD SWITCH GEAR HIGH SPEED BUS TRANSFER RELAY-BECKWITH MODEL M-0272-0236B RELAY 380V LV SWITCHGEAR BLOKSET-INSTRUCTION MANUAL LV POWER CIRCUIT BREAKERS-MASTERPACT NT AND NW-CATALOGUE 2003 380V MCC BLOCSET-INSTRUCTION MANUAL. LV POWER CIRCUIT BREAKERS-COMPACT NS. CATALOGUE 2002 AC DISTRIBUTION PANEL DC SYSTEM UPS SYSTEM AUXILIARY MOTORS COMMUNICATION SYSTEM CLOCK SYSTEM LIGHTING SYSTEM CLOSED CIRCUIT Tv SYSTEM STDC STARTER PANEL 180 KV SUBSTATION Contents PAGES 47-91 47-147 4.7-239 48-1 48-3 48-75, 49-1 493 4.9-75 410-1 441-1 4.12-1 413-1 441441 415-1 4.16-1 4.17-1 4.18- 1 419-4de MITSURISHE 3 MECHANICAL ‘MHI Proprietary Informationabe METRUBISH 3.21 SCREEN SYSTEM KKS NUMBER : 10PAA01SS101 ‘MHI Proprietary information3.21.1 STOP LOG & STORAGE KKS NUMBER : 10PAA01AB101/102 ‘MHI Proprietary informationte MITSUBISHI- 3.21.1 Stop Log & Storage MITSUBISHI HEAVY INDUSTRIES, LTD. Takasago Machinery Works Operation Manual ‘MHI Proprietary Information 321-4Intentionally Blank ‘MF Proprietary Information 3.21-2OPERATION MANUAL STOP LOG & STORAGE 3.21-3Intentionally Blank 3.21-4(€8206-NTA7979-11-OM-BAT-rev1 EBS « wnonerace Operation Manual INDEX OF PAGES Page | Date | Rev. Page | Date | Rev. | s076ares |" T +7 [200905 | 7 2 [20/09/05 [ + 72 | 20/09/05) 1 3___|4o/0a05| 0 73” [10/03/05 | 0 4 AQ/O3/05_ o 44 10/03/05 0 [10/03/05 [0 45 [10/03/05 0 6 [40/03/05] 0 76 [40/03/05 0 7 [10/03/05 | ~o 47 [40/03/05 ) 0 [10/03/05 [0 18 [10/03/05] 0. 9 | 40/03/05 [0 19 | 40/03/0510 40 20/09/05 1 20 40/03/05. o TE BEAUDREY & Che vsrsal righ on i vue tos Wa be poder a ay fav Wild Hs WED ST IF IN DOUBT ASK Page :2 321-5(©8206-NTA7979-11-OM-BAT-rev0 E, BEAUDREY & Ci € B ° Operation Manuat TABLE OF CONTENTS COVER SHEET. INDEX OF PAGES TABLE OF CONTENTS ‘SAFETY AND WARNING INSTRUCTIONS .. FOREWORD... 4. GENERAL. 4.1. SCOPE OF SUPPLY, 1.2. LIST OF APPLICABLE DOCUMENTS 2. DESCRIPTION 2.1. MAIN DATA. 241 General. 24.2 Stop iog 2.4.3 Cathodic protection 2.2 GENERAL DESCRIPTION 2.2.1 Main sub-assembiies .. 2.2.2 Description of main sul Cathodic protection 3. OPERATION 3.1. GENERAL 3.2 FIRST START-UP AND START UP AFTER INTERVENTION. 3.2.1 First stareup.. cn 3.2.2 Start-up after interventior 3.3 NORMAL OPERATION... 3.3.1 Start-up operations. 3.3.2 Manual mode.... 3.4 CHECKING INSTRUCTIONS IN NORMAL CONDITIONS . 3.5 SHUT-DOWN OPERATIONS... 4, INCIDENTS, CAUSES AND REMEDIES... 4.1 INSTRUCTIONS IN CASE OF ALARM SIGNALLING... 6. DRAWINGS... 6.1 GENERAL DRAWING...... 6.2 OPERATION DRAWING. TE BEAUDREY & Cre reves al gion it dovumons Dt can fol be rprodsed ay Pa Suh He WEN CONE IF IN DOUBT ASK Page:3 3.21-6C8206-NTA7979-11-OM-BAT-revd E, BEAUDREY & Clo € DB Operation Manual SAFETY AND WARNING INSTRUCTIONS subjected to very aggressive operating conditions including wear, corrosion, growth, abrasion etc. The machines are designed for such a service but it generally impossible to provide safety equipment inside as it would suffer as much as the remainder of the equipment and e could not be trusted for safety purposes. Each time work is required, it should be carefully planned, executed and supervised according toa specific safety plan. Personnel should be instructed thoroughly of the dangers and safety measures before proceeding. Adequate first-aid facilities must be available at ail times. ‘The instructions marked AL in the following tables are to be respected in order to avoid corporeal accident, Itis to be noted that BEAUDREY’s supply is only a part of the concemed system, All safety- related matters must be handled by the operator on a global basis including civil engineering, pipe-work, electrical equipment, neighbouring equipment, plant operating sequences etc. ‘Whenever in doubt as to how to proceed, do not hesitate to ask BEAUDREY. These instructions are only recommendations, an risks analysis must be perform to adapted the site safety measures according to the country's statutes. TE BEAUDREY & Cre reserves al righie on this dooumet hal an ot be epreaced IF IN DOUBT ASK Page: 4 Par witout Hs won combo. 3.21-7(€8206-NTA7979-1 1-OM-BAT-rev0 E. BEAUDREY & Ch €® ° Operation Manual SG: Ds: TBS: Sluice gate Trash rake Drum screen Travelling band screen Debris fitters SG IR B bs TBS SAFETY WARNING / ATTENTION Never attempt to work on the machine without cutting the power AX supply in such a manner that it cannot be switched on until the work is finished (locks, guard, etc.) Never enter the pipe work without making sure it has been cleaned and is correctly ventilated. Always have a person outside keeping watch, ‘Ay Take extra care when entering the machine or pit ae al surfaces might be slippery owing to sludge, growth, ete. A ‘Take extra care when entering the machine or pit as shell growth results in cutting edges. A Check the pipe work and/or pit for presence of HeS and other toxic decay-related gases. Do not enter until it has been eliminated. Never act alone on the machine. Have a person watching out for all A safety-related matters correctly instructed as to what must be done in case of emergencies. Never intervene on any part of the supply without a full, duly-signed Ay safety pian in compliance with the operator's country and/or corporate requirements and laws. ‘Take all necessary measures to prevent falls in the pits, pipes, ete (hamess, safety rope, nets, scaffoldings, temporary or permanent hand railing, pit covers, tadders, ete.).. ‘Ay Newer enter a pit o pipe without having taken all measures to prevent the accidental ingress of water. TE BEAUDREY & Ci roars al nae on tis docuret thal can ot be Teprodacod I by po witow fa writen corse IF IN DOUBT ASK Page : 5 3.21-8©8206-NTA7979-11-OM-BAT-rev0 EB essere Operation Manuat sc: Sluice gate T Trash rake Drum sereen TBS: Travelling band screen WwW: Debris filters glelsiBls SAFETY WARNING | ATTENTION x] x] x}x]x Never attempt to enter a machine in operation or with water flowing AS through x] x]x]x]x| qa. Owing tothe presence of water andlor dampness, never use e electric tools with a voltage exceeding 12 voits. x] x |<] x]. Never attempt any acivity in the machine without having installed safe and adequate lighting in all areas. xx] x] x] x Never start any work on a machine before having Informed and AX Obtained permission from the main control room of the plant and/or the operations superintendent. x)|x]x[x]x Do not remove covers, guards or open hatches or manholes until the machine is stopped, power cut and all other safety measures implemented. x]eieT | ay Do not attempt to pick or catch any item lifted out of the water by the machine x} x] x]x Never try to stop or alter the operation of the machine by artificially Ay activating the limit switches, either mechanically or by straps in the PLC cabinets. x |x| x |x| AX Do not disconnect any safety or warning system x|x|x]x]x Before starting any work, fence and/or control access to the working AX Zone and install warming posters to keep out all unauthorised personnel, x] xx] x]x| 4 Before any iting operation, make sure that al iing tackle and systems meet regulatory requirements. xPx Ex] x| x] Always allow for a substantial load safety margin for alt lifting systems and tackles when lifting all or part of a machine. TE BEAUDREY & is onrver ll righs on tis Gocumen fu can ot be eproduced hoy pan woul Es win conse IF IN DOUBT ASK Page: 6 3.218(€8206-NTA7879-11-OM-BAT-rev0 E. BEAUDREY & Cie € DB Operation Manual SG: Sluice gate TR Trash rake Ds: Drum screen TBS: Travelling band screen Ww Debris fitters gleis|zis SAFETY WARNING / ATTENTION xx] x]x] x]. Before any liting operation, clear all personnel from the zone where the equipment might fall if@ lifting tackle breaks, x[x|x] x] x] AX Always use trained and/or licensed crane operators. xix] x] x] x Never try and reach any part of a machine in service not accessible A\, without having to either open a normally-closed inlet and/or requiring the use of temporary access systems (ladders, scaffolding). x ‘Always check stop logs / dam boards / sluice gates before use. ‘There must be no heavy corrosion, no corrosion pits, no weld crack, When in doubt, call BEAUDREY for assistance. x Never send operators in pits that are kept dry by stop log(s} without AX checking the civil engineering and ground around the stop log guide area. xfo]x]x] |. When working under the protection of a stop fog / dam board / slice gate, provide adequate bilge pumps including stand-by pumps. x|x[x]x]x ‘When working in the machine, provide adequate, safety-authority AX approved scaffoldings, ladders, platforms, gangways and other temporary work stations. x1 x]|x] x] x When touching-up paintwork, take required precautions for venting, Ay aerating. Wear protective clothing (masks, hoods, suits) as required by the paint category (see its labelling). x] 4. De notwold insite or on the fiter shell as itis rubber-ined andlor painted. This might cause a fire. TEEAUDREY & Cie eocres Al lgho ov Ws davai hacen not bo proud vy par wiser wen Come IF IN DOUBT ASK Page:7 3.21-10(C8206-NTA7979-11-OM-BAT-rev0 €5 E, BEAUDREY & Cie | Operation Manuat Sluice gate Trash rake Drum screen Travelling band screen Debris filters Bie) a B= ‘SAFETY WARNING / ATTENTION x]x]x]x}x Never do any welding work close to or on the machines without a Ad| safety-authority compiiant or approved fire prevention plan and e associated equipment x|x|x|x]x] >] When in doubt about any work or supply, call BEAUDREY for assistance or personnel instruction. x] x] x]x}x Never trust the resistance / strength / reliability or any internal part as it might have weakened, decayed, corroded , broken or become loose due to operation. It must be fully Inspected and assessed before being used, x| x (Ag| Never litany large area item (stop log, barrack, cover, etc) when the wind speed might be a hazard. x[x]x| «| a | Disconnect as many sources of supply as possible before carrying out any work on the equipment, x|x]|x| x Never run a filter empty except for the maintenance operation. x{x]x]x]x For the maintenance operations on stainless stee! component, only stainless stee! tools must be used. @ ixixixlxlx It is imperative to lay the both contact surfaces with “filorisé” coating when gathering together two parts made with stainless steel. x] x] x) x In no case should the equipment stay in stagnant water, TE BEAUDREY & Cle ecorver al ight on Wis Gpcumcn fa can sot be reproduce uray pk wont Hs writen conser IF IN DOUBT ASK Page :8 321-11(©8206-NTA7879-11-OM-BAT-revO0 EB «sconce Operation Manual FOREWORD This manual has been established to enable the operating and maintenance teams to operate the equipment described in the present manual. This document is based on the assumption that the teams are qualified personal and fully acquainted with the general rules. Therefore, the manual gives the main instructions to perform the necessary tasks. HOWTO USE 7! AL, This document lists the equipment’s parts. Itis important to exactly follow the instructions given in this Manual. They are simple precautions but essential for the equipment's correct operation. The equipment must not be modified in any way and only normal maintenance operations as described in this manual must be performed on the equipment, Failure to respect these instructions may lead to serious damage, which could, in no way, be covered by the warranty clause of the contract. ‘When communicating with BEAUDREY, please indicate the BEAUDREY order N° shown on the first page. Parts subject to wear: spare parts We particularly suggest keeping a stock of parts subject to wear during normal operation. All of these parts are indicated in the Recommended spare parts document. Furthermore, we also suggest the operator to have a spare drive motor in stock. How to order spare parts 2 Indicate - The BEAUDREY ordernumber —¢ 8206 The part number and name (as identified in the parts list), — The type ofequipment STOP LOG = The required quantity. BEAUDREY can in no Way be held responsible if these instructions are not followed, Do not install parts not supplied by BEAUDREY. Our experience has shown that despite identical appearance, quality is general insufficient and leads to expensive accidents. TE BEAUDIEY & Cie ores al digas on ils damon ht can wot be eprodced In ay part witha fy when cons IF IN DOUBT ASK Page : 8 3.21612(€8206-NTA7979-11-OM-BAT-rev4 E, BEAUDREY & Cio EB Operation Manual 1. GENERAL 4.4 SCOPE OF SUPPLY Refer to stop log general arrangement drawing (paragraph 5.1). The delivery equioment is: QUANTITY EQUIPMENT [Sel of stopilogs 1 Lifting beam 1 ‘Stop log storage rack 2 Bar screens 41 Mobil trash rake 2 Travelling band screen with wash water device 4.2. LIST OF APPLICABLE DOCUMENTS, The following list indicates the corresponding reference of all documents quoted in the Operation Manual. Drawing Number Title Customer BEAUDREY NTA7977__ | Commissioning Procedure £ 102290 | ‘P&l Diagram Unit NTA 7979-12 Maintenance manual Please refer to last revision of documents. docu "E BEAUDREY & Cie rosrvesall gis ons dooaen Woah 2 bs fpvodueed nay Pat wins wi CONE IF IN DOUBT ASK Page : 10 3.21-13C8206-NTA7979-11-OM-BAT-rev1 E, BEAUDREY & Cie " Operation Manuat 2. DESCRIPTION 2.4 MAIN DATA 2.4.1 GENERAL EQUIPMENT DATA Fluid Sea water Highest water level (HWL) +0.64 m Lowest water level (WL) “47m Service deck level +3.55 m Invert level -7,.08 m 2.1.2 STOPLOG EQUIPMENT DATA Aperture dimensions - Height 7.500 m = Width 5.112m Number of element per gate 3 Balancing valve - Quantity 2 - Diameter 100 mm Handling ~ Lifting beam capacity Tt - Lifting height for removing the gate from the operating position to the storage or 6.80m maintenance position 2.1.3. CATHODIC PROTECTION Refer to Cathodic Protection System. TE BEAUDREY & ie vesvev al igh ns doco TA AN PotD FeROUESH yar wou ERC oe IF IN DOUBT ASK Page: 14 321-14(C8206-NTA7979-11-OM-BAT-revt € B E. BEAUDREY & Cie 5, Operation Manual 2.2 GENERAL DESCRIPTION Refer to stop log general arrangement drawing (paragraph 5.1). 2.2.1 MAIN SUB-ASSEMBLIES ‘The stop log equipment mainly consist of : — Three gate's elements, — Two balancing valves, ~ Abalancing valve actuating device - Asset of guides, ~ Asset of sacrificial anodes, - Aiifting beam. ~ Astorage rack. 2.2.2 DESCRIPTION OF MAIN SUB-ASSEMBLIES 2.2.21 Gate The gate consists of one back plate, stiffeners, three frame element, on which the water- tightness is obtained by a peripheral seal. The gate is equipped with: ~ Two balancing vaive located on the up-stream of the bottom gate element and operated automatically by means of the lifting beam, — One sealing device comprising peripheral seais, seal securing flats and fastening bolts, 2.2.2.2 Lifting beam The lifting beam is used to handle the stop log, It disengages automatically when the stop log take place in the channel. 2.2.2.3 Set of guides It includes one bottom sill and two vertical guides. The different elements are fitted together to form a rigid frame. Welded grouting lugs on still and vertical guides enable the frame to be fixed in the concrete. 2.2.3 CATHODIC PROTECTION Refer to Cathodic Protection System. 2.24 STORAGE RACK The storage rack is composed of a set of poles and supports bolted in the concrete at deck level, 2.2.6 ASSOCIATED COMPONENTS Not applicable. TE REAUDREY & Cie revervesdil gh on @s document hat cannot be reproeined I ny par WIR Wen aS. IF IN DOUBT ASK Page : 12 3.2115€8206-NTA7979-11-OM-BAT-rev0- E B E, BEAUDREY & Cie Operation Manual 3. OPERATION 3.1 GENERAL The stop log may take place in the channel, or in the storage place. 3.2 FIRST START-UP AND START UP AFTER INTERVENTION 3.2.1 FIRST START-UP. Refer to last revision of Commissioning procedure document (refer to paragraph 1.2) 3.2.2 START-UP AFTER INTERVENTION Check that the maintenance operations are carried out. — Verify that no tools have been left on the working area. = Check that the gate’s seals are in a good state and shape. — Check there is no object wedged in the guides or left on the bottom sill. ~ Check there is no circulation pump in operation. ~ Set the bottom stop log element in the pit (refer to drawing NA 14054 in paragraph + Disengage the locking cams, + Hang-up the lifting beam on the hook of crane, and set it down to the stop log element, + Centre the lifting beam “ and stop the downward travel when cable begin to slack, + Lift up the stop log element, > the two hooks catch the stop log, > the hooks are locked. + Engage the security pins to lock the hooks, + Place the stop log element above the pit (the gate's seal regarding the downstream), + Centre the stop log element into the guides and set it down, + Stop the downward travel at deck level, + Remove the security pins, + Rotate the locking cams against the hooks, + Hang-up the balancing valve's cable on the hook located on the concrete, + Stop the downward travel when the cable begin to slack; the hooks opens automatically, + Lift up the iifing beam, — Perform the same operations to set the top stop log element in the pit = Check that the balancing valve actuating device is on close position (fully unscrewed), ~ Call for pumping and drain dry the downstream channel. Toke care fo the Ming boar enontation TE, BEAUDREY Cie resores al righ on tis Gocuw va oa ot be eprodue nny Far WOU Hr Hen const IF INDOUBT ASK Page : 13, 3.21-16(C8206-NTA7979-11-OM-BAT-revO € B E, BEAUDREY & Cie Operation Manual ~ During the channel's water pumping, inspect the stop log’s water-tightness. — Cary out a watertighiness test of the stop log when the gate is withstanding under the maximum water column (Refer to Maintenance manual) 3.3 NORMAL OPERATION 33.4 START-UP OPERATIONS Refer to paragraph 3.2.2 3.3.2 MANUAL MODE Itis possible to unlock the lifting beam's hooks by manually tilt over the hook’s locking cam. TE BEAUDREY & Clo vores ol ghia on ts dosent ta om ot be rprodleed in Gay par whut Wren const, IF IN DOUBT ASK Page :14 3.214768206-NTA7979-11-OM-BAT-rev0 E. BEAUDREY & Cle € BD Operation Manuai 3.4 CHECKING INSTRUCTIONS IN NORMAL CONDITIONS ~ Check that there is no significant leakage (exceeding the performance mentioned in the Maintenance manual), ~ Check that there is no fouling on the guides, nor accumulated debris against the gate. 3.5 SHUT-DOWN OPERATIONS Refer to drawing NA 14085 in paragraph 5.2. — Make sure that down-stream channel may be flooded, Check that there are no pumps of the clrouit in operation, - Perform the balancing water level operation : + Open the balancing valve by mean of the operating cables winch, + Wait for upstream and downstream water level equilibrium. — Lift up the top stop log element : + Disengage the locking cams, + Hang-up the lifting beam on the hook of crane, Centre the lifting beam " and stop the downward travel when cable begin to stack, > the two hooks catch the stop log, } the hooks are locked. Lift up the top stop log element and stop the upward travel at deck level, Hang-up the balancing vaive’s cable on the hook located on stop log, Engage the security pins to lock the hooks, ~ Storage the stop log element, + Lift up the stop log element, + Place the stop log element above the storage rack, + Remove the security pins, + Centre the stop log element into the rack and set it down, + Stop the downward travel when the cable begin to slack, + Rotate the locking cams against the hooks, + Stop the downward travel when the cable begin to slack ; the hooks opens automatically, + Lift up the lifting beam, + Storage the lifting beam, — Rinse the stop log, the seals and the lifting beam with no salt clean water. — Inspect the seals, Clean and protect them (Refer to Maintenance manual) — Make the necessary repairs or replacement before to store the gate (Refer to Maintenance manual). “Teka gare to tha tting boam ofantation "E BEAUDREY & Cio exorve al igus onthi osunsan at can foi be yvoduced Wey ball WAM Ky Wien cone IFN DOUBT ASK Page: 15 3.21-48C8206-NTA7979~11-OM-BAT-rev0 a € E, BEAUDREY & Cie Operation Manual 4. INCIDENTS, CAUSES AND REMEDIES SAFETY WARNING Under no circumstances are divers to be allowed fo work until all wedged equipment has been safely propped up against invert 4.1 INSTRUCTIONS IN CASE OF ALARM SIGNALLING Not applicable. TE BEAUDNEY & Cie roars vgn on Is doctor can it De oproduced ay prt obo 1 Wien COE JF IN DOUBT ASK Page: 16 3.21-19(C8206-NTA7979-11-OM-BAT-rev0 Operation Manual 5. DRAWINGS 5.1 GENERAL DRAWING The following drawings are delivery separately Drawing Number Title Customer /BEAUDREY E 102418 | Intake screening equipment General arrangement D 102443 | Stop og general arrangement E 102626 | Lifting beam & handling D 102924 | Stop log storage TE BEAUDREY & Ch essrreallighson vs docu ha cent We prods i any pan Wier Hs HH conse IF IN DOUBT ASK Page : 17 3.21-20(€8206-NTA7979-t1-OM-BAT-revo E. BEAUDREY & Cle € D Operation Manual 5.2 OPERATION DRAWING Drawing Title NA 14054 ‘Stop log handling and instaliation operation NA 14055 __| Stop log handling and removal operation TE WEAUDREY & Che resercr al igh on Us Goce at can ot Be rorodueod apa Wilout is Wien conse IF IN DOUBT ASK Page : 18 321-24NA 14054.xIs_ B. BEAUDREY 4 Cle 1” TAKE OFF THE GATE FROM THE STORAGE RACK, 2 ~ HOOKS ENGAGING PRELEVEMENT DU BATARDEAU DANS LE GARAGE ENGAGEMENT OES CROCHETS 3— HOOKS LOCKING ‘4 ENGAGING OF SECURITY PINS DURING HANDLING. VERAOUILLAGE DES CROGHETS 1 (OPERATION MISE EN PLACE DES GOUPILLES DE SECURITE PENDANT LA MANUTENTION S. ASS. Drawing Nr./PlanN’ Rev. 1100 NA 14054-4 0 TE. BEALIDREY & Cie reservas all ight on this document that ar not be reproduced in ary pvt without ls writen consent. Co document appariont a €. BEAUDAEY 8, Cle. Tout reproduction, méme pale ne paut re fate sans sor consertamert Gok IF IN DOUBT ASK 3.21-22NA 14054.x1s [E, BEAUDREY & Cie 8 HOOKS ARF LOCKED AFFER CAMS TILTING. =. en ITY & ENGAGE 8 ABOVE GUIDES, REMOVE FS SECUTETY 8 ENGAG: HOOKS AR vs AU.DESSUS DES GUIDAGES, ENLEVER LES GOUPILLES ‘BASCULEMENT DES VERROUS DE SECURITE ET BASCULER LES VERROUS ‘8EXTRACT THE LIFTING BEAM EXTRAIRE LE PALONNIER PLACE THE 2 CAMS IN THE INITIAL POSITION (SEE POINT 1) REPLACEA LES 2 VERROUS DANS LEUR POSITION INITIALE (WoIR POINT 9) ENGAGE THE 2 SECURITY PINS DURING HANDLING. PLAGEA LES 2 VERFIOUS PENDANT LA MANUTENTION PLACE THE LIFTING BEAM IN STORAGE RACK a STOCKER LE PALONNIER DANS LE GARAGE A BATARDEAUX 17=UFTING BEAM GOING UP 'RELEVAGE OU PALONNIER 8. ASS. Drawing Nr./PlanN’ Rev. 1100 NA 14054-2 o IE. BEAUDAEY & Glo reserves af ghis on tls deeuanent that ean not be reproduced in any part without ls writer consent ‘Ce document apparent & E, BEAUDREY & Cis. Toute reproduction, méme parila ne peut éte fale sans son consentement éait. IF IN DOUBT ASK 3.21-23@ NA 14055.x18. E.BEAUDREY.4 Ge 1 UPSTREAM AND DOWNSTREAM LEVEL MUST BE 2 TAKE OFF THE LIFTING BEAM FROM THE BALANCED STORAGE RACK .SORTIF LE PALONNIER DU GARAGE A BATARDEAUX ‘3 CHECK LIFTING BEAM ORIENTATION AND PLAGE THE GATE ABOVE GUIDES. CONTROLER L/ORIENTATION DU PALONNIEA ET PLACER LE BATARDEAU A L/APLOMB DES GUIDAGES 5. ASS. Drawing Nr./PlanN* Rev. 1100 NA 14055-1 0 'E.BEAUDREY & Cie reserves al ights on tis document tat ean not be reproduced in ary pert winout is writ consent. (Ge document aopartent &E. BEAUDAEY & Cl, Toute reproduction, mBme patiede ne pout bie fate ean con consenternant Sct. IF IN DOUBT ASK 3.21-24NA 14088.xI8, E BEAUDREYS Ce I GOING DOWN THE LIFTING BEAM IN GUIDES TLL THE 8- HOOKS TILTING GATE BASCULEMENT DES CROCHETS DESCENDRE LE PALONINIER JUSQUAU BATARDEAU / =| Cu 1 8~ EXTRACT LIFTING BEAM AND GATE SeaTac GRANT EXTRAIBE LE PALONMIER ET LE BATARDEAU CROCHETS VERROUILLES (GRAVITE) [STORE GATE AND LIFTING BEAM IN THE STORAGE RACK [STOKER LE PALONVIEH DANS LE GARAGE A BATARDEALX ASS. Drawing Nr./PlanN’ Rev. 1100 NA 14055-2 0 TE. BEAUDREY & Cio reserves af ights on this doournont thal can notte reproduced in any par wiht is wlen consort, ‘Ce docurent apparllnt & E. BEAUDREY & Cio. Toul roproducton, mime parila ne peut ire fel sans son consentsinent Gos. SF IN DOUBT ASK. 3.21-25Intentionally Blank 3.21-26fe MET SURISHE- 3.21.2 BAR SCREEN & TRAVELING TRASH RAKE KKS NUMBER : 10PAA01AT101/102 10PAA01AT201/202 (MH! Proprietary Infomation3.21.2 Bar Screen & Traveling Trash Rake MITSUBISHI HEAVY INDUSTRIES, LTD. Takasago Machinery Works Operation Manual ‘MH Propristary Information 3.21-27fe MITSUBISHI Intentionally Blank |i Proprietary infermetion 3.21-28OPERATION MANUAL BAR SCREEN & TRAVELLING TRASH RAKE 3.21-28Intentionally Blank 3.21-30(€8208-NTA7979-21-OM-DEG-revi E. BEAUDREY & Cle @ Operation Manual INDEX OF PAGES Page Date Rev. Page Date Rev. Page Date Rev. 4 20/09/05 1 46 24/01/05 0 34 24/04/05 oO 2 [20/08/05| 4 47__|20/0a/05| “4 32 [24/07/05 |_ 0 3 ]24/01/05 10 18 |24/01/05| 0 ‘Appen. 1 ]24/01/05| 0 4 [24/0105 0 ig |2a0u0s| 0 ‘Appen.2 | 24/01/05] 0 52410105) 0 20 [20/09/05 4 ‘Appen. 3 [24/01/05 | 0 6 [24101705 ) _0 21__[2a/oios! 0 ‘Appen.4 24/01/05! 0 7 [2aloifos| 0 22° |24/0i/05} 0 (Aopen. 5124/01/05; 0 8 24/01/05 oO 23 24/01/05 oO 9 24/01/05. oO 24 24/04/05, oO 40 24/01/05 o 25 24/09/05, o 41 20/09/05 4 26 24/01/05 9 @ |_2_[xons |e 2724/01/05] 0 43 24/01/05 o 28 24/01/05. 0 14 24/01/05. 0 29 24/0105 oO 15 24/01/05. 0 30 24/0 1105, 0 "EBEAUDREY & Go overvenal rights ond dacament bean noe eqrediond Bony Pat who Rs wien come IF IN DOUBT ASK Page: 2 3.21-31(C8206-NTA7979-21-OM-DEG-revd E. BEAUDREY & Ci € D ° Operation Manual COVER SHEET... INDEX OF PAGES ......00 SAFETY AND WARNING INSTRUCTIONS, FOREWORD... 1. GENERAL... 1.1. SCOPE OF SUPPLY.. 1.2 LIST OF APPLICABLE DOCUMENTS.. 2, DESCRIPTION. MAIN DATA.. General Bar soreen Trash rake. Hoist driving unit. Hoist cable Travel car driving unit, Cable winding device driving unit Head-loss detection devices Cathodic protection . Wash-water device. 2.2 GENERAL DESCRIPTION 2.2.1 Main sub-assemblies. 2.2.2 Description of main sub-assembii 22.3 Wash-water supply device 2.24 Cathodic protection 2.2.5 Trash basket... 2.2.6 — Associated components 3, OPERATION 3.1 GENERAL 3.2 FIRST START-UP AND START UP AFTER INTERVENTION 3.2.4 First start-up. 3.22 — Start-up after intervention 3.3 NORMAL OPERATION 3.3.1 Start-up operations 3.8.2 Automatic mode 3.3.3 Manual mode .. 3.4 CHECKING INSTRUCTIONS IN NORMAL CONDITIONS .. 3.4.1 Automatic mode 3.4.2 Manual mode .. 3.5 SHUT-DOWN OPERATIONS. 4, INCIDENTS, CAUSES AND REMEDIES. 4.1 INSTRUCTIONS IN CASE OF ALARM SIGNALLIN cm Vob bone 3 B88eee VissaaSSNOHK AE3 Saws 2 TELDEAUDREY & Go reserves si igh onl docarant Hal canotbe reproduced any partwihou Fe IF IN DOUBT ASK Page: 3 3.21-32©8206-NTA7979-21-OM-DEG-revo € E, BEAUDREY & Cio Operation Manual 5. DRAWINGS.. 5.1. GENERAL DRAWING. §.2 OPERATION DRAWING.. TEIDEAUDREY & Gierceaves all igh on ie dosomen hn con hot Do oprodueed ia any pa wit swine Sonat IFN DOUBT ASK Paga:4 3.21-33,(©8206-NTA7979-21-0M-DEG-rev0 EB « wrsrvace Operation Manual SAFETY AND WARNING INSTRUCTIONS BEAUDREY equipment is designed for fully automatic, unmanned operation in general. It is subjected to very aggressive operating conditions including weer, corrosion, growth, abrasion etc, The machines are designed for such a service but it generally impossible to provide safety equipment inside as it would suffer as much as the remainder of the ‘equipment and could not be trusted for safety purposes. Each time work is required, it should be carefully planned, executed and supervised according to a spectic safety plan. Personnel should be instructed thoroughly of the dangers and safety measures before proceeding. Adequate first-aid facilities must be available at all times. The instructions marked A\ in the following tables are to be respected in order to avold corporeal accident. itis to be noted that BEAUDREY’s supply is only a part of the concemed systern All safety-related matters must be handled by the operator on a global basis including civil engineering, pipe-work, electrical equipment, neighbouring equipment, plant operating sequences etc. Whenever in doubt as to how to proceed, do not hesitate to ask BEAUDREY. ‘These Instructions are only recommendations, an risks analysis must be perform to adapted the site safety measures according to the country's statutes. TE BEAUDREY & Gis river al iis o> it docement lca nol be opotee= IF IN DOUBT ASK Page :5 ma 3.21-34s@: Sluice gate (©8206-NTA7979.21-OM-DEG-revo Operation Manwal TR: Trash rake Ds: Drum screen TBS: Travelling band screen WwW Debris filters BIEIS 8 2 SAFETY WARNING / ATTENTION x|x]x]x ‘Never attempt to work on the machine without cutting the power supply in such a manner that it cannot be switched on until the work. is finished (locks, guard, etc.) e x Never enter the pipe work without making sure it has been cleaned Ay and is correctly ventilated, Always have a person outside keeping watch. . x1 xX) x) xx A ‘Take extra care when entering the machine or pit as all surfaces might be slippery owing to sludge, growth, etc. x[x]x]x] x14 Take extra care when ntering the machine or pitas shell growth results in cutting edges. x] x] x] x] x | 4. Check the pipe work andlor pit for presence of HeS and other toxic decay-related gases. Do not enter until it has been eliminated. x|x|x]x [x Never act alone on the machine. Have a person watching out for all Ay Salety-related maiters correctly instructed as to what must be done in case of emergencies. x] x] x] x] x Never intervene on any part of the supply without a full, duty-signed safety plan in compliance with the operator's country and/or e corporate requirements and laws, x] x] x] x} x Take all necessary measures to prevent falls in the pits, pipes, ete AX (hamess, safety rope, nets, scaffoldings, temporary or permanent hand railing, pit covers, ladders, etc.). x] x]x/x] x] 4 Never enter a pit or pipe without having taken all measures to prevent the accidental ingress of water. ny pa wet Ts we OE IF IN DOUBT ASK Page :6 3.21-35©@® E, BEAUDREY & Cio . 8a: TR: Ds: TBS: W: Sluice gate ‘Trash rake Drum screen Travelling band screen Debris filters (€8206-NTA7979-21-OM-DEG-rev0 Operation Manual ° a TR DS a SAFETY WARNING / ATTENTION A Never attempt to enter a machine in operation or with water flowing through, | A ‘Owing to the presence of water and/or dampness, never use electric tools with a voltage exceeding 12 volts. A Never attempt any activity in the machine without having installed safe and adequate lighting in all areas. Never start any work on a machine before having informed and obtained permission from the main control room of the plant and/or the operations superintendent. Do not remove covers, guards or open hatches or manholes until the machina is stopped, power cut and all other safety measures implemented. A Do not attempt to pick or catch any item lifted out of the water by the machine A Never try to stop or atter the operation of the machine by artificially activating the limit switches, either mechanically or by straps in the PLC cabinets. A Do not disconnect any safety or warning system Before starting any work, fence and/or control access to the working Zone and install warning posters to keep out all unauthorised personnel. A Before any lifting operation, make sure that all lifting tackle and systems meet regulatory requirements. A Always allow for a substantial load safety margin for all lifting systems and tackles when lifting all or part of a machine. TE DRAUDRIY & Ge roves ll rigison bs docu can nt be reproduc Tn ay port widoat Ba writen consent IF IN DOUBT ASK Page: 7 3.21-36(C8206-NTA7979-21-OM-DEG-rev0 E. BEAUDREY & Ci " € ° Operation Manual SG: Sluice gate TR: Trash rake DS: Drum screen TBS: Travelling band screen Ww: Debris filters glejalal= SAFETY WARNING / ATTENTION x [x] ) x] x] 4 Before any titing operation, clear ll personnel fom the zone where the equipment might fal fa lifting tackle breaks. x} x| x1 x|x| AX Always use trained and/or licensed crane operators. x[x]x]x]x Never try and reach any part of a machine in service not accessible A\ without having to elther open a normally-closed inlet and/or requiring the use of temporary access systems (ladders, scaffolding). x Always check stop logs / dam boards / sluice gates before use. There must be no heavy corrosion, no corrosion pits, no weld crack. When In doubt, call BEAUDREY for assistance. x Never send operators in pits that are kept dry by stop log(s) without checking the civil engineering and ground around the stop log guide area, x[x]x]x|_ |. When working under the protection ofa stop log / dam board / suloe gate, provide adequate bilge pumps including stand-by pumps. x |x| x] x] x ‘When working in the machine, provide adequate, safety-authority AX approved scaffoldings, ladders, platforms, gangways and other temporary work stations, x|x|x]x]x ‘When touching-up paintwork, take required precautions for venting, AX aerating. Wear protective clothing (masks, hoods, suits) as required by the paint category (see its labelling}. x] Ay Do not weld inside or on the fter shell as itis rubber-ined and/or painted. This might cause a fire. TELBEAUDREY & Cle serves all igh ons dosumen ta canoe IFIN DOUBT ASK Page : 8 3.21-37(©8206-NTA7979-21-OM-DEG-rev0 EBS msnnr ace Operation Manual Sluice gate Trash rake Drum sereen Travelling band screen Debris filers glejaial= SAFETY WARNING / ATTENTION x|x[x]x]x Never do any welding work close to or on the machines without a AN| safety-authority compliant or approved fire prevention plan and associated equipment. x| x lx] x| x When in doubt about any work or supply, call BEAUDREY for assistance or personnel instruction. x|x[x}x]x Never trust the resistanée / strength / reliability or any internal part as it might have weakened, decayed, corroded , broken or become loose due to operation. It must be fully inspected and assessed before being used. x| x ‘Ay| Never litany large area tem (stop log, barrack, cover, ete.) when the wind speed might be a hazard. xx] | | Disconnect as many sources of supply as possible before carrying out any work on the equipment, xix] x| x Never run a filter empty except for the maintenance operation. x|xfxjx!x For the maintenance operations on stainless steel component, only stainless steel tools must be used. x{x]x]x{x itis imperative to lay the both contact surfaces with “filorisé* coating when gathering together two parts made with stainless steel. x] x] x In no case should the equipment stay in stagnant water. TE BEAUDREY & Glefesures oD this on i docornnt tht cn IF IN DOUBT ASK Page :9 rade ney Par WOO TS WED COREE, 3.21-38(©8206-NTA7979-21-OM-DEG-rovo E, BEAUDREY & Cle € S Operation Manual FOREWORD This manual has been established to enable the operating and maintenance teams to operate the equipment described in the present manual. This document is based on the assumption that the teams are qualified personal and fully acquainted with the general rules. Therefore, the manual gives the main instructions to perform the necessary tasks. HOW TO USE THIS MANUAL This document iists the equipment's parts. Itis important to exactly follow the instructions given in this Manuel. They are simple precautions but essential for the equipment's correct operation. ‘The equipment must not be modified in any way and only normal maintenance operations as described in this manual must be performed on the equipment. Failure to respect these instructions may lead to serious damage, which could, in no way, be covered by the warranty clause of the contract. When communicating with BEAUDREY, please indicate the BEAUDREY order N* shown, on the first page. Parts subject to is arts We particularly suggest keeping a stock of parts subject to wear during normal operation. All of these parts are indicated in the Recommended spare parts document. Furthermore, we also suggest the operator to have a spare drive motor in stock. How to order spare parts ? Indicate : - The BEAUDREY order number © 8206. - The part number and name (as identified in the parts list), - The type of equipment MOBILE TRASH RAKE S TYPE + The required quantity. BEAUDREY can in no way be held responsible if these instructions are not followed. Do not install parts not supplied by BEAUDREY. Our experience has shown that despite identical appearance, quality is genoral insufficient and leads to expensive accidents. SUDREY & Cie reserven ign on thls Socument ncn norte reprodicod Ta any pak wil ls ween canal, IF IN DOUBT ASK Page : 10 3.21-39€8206-NTA7979-21-OW-DEG-revt Operation Manual 4. GENERAL 4.1 SCOPE OF SUPPLY Refer to trash rake general arrangement drawing (paragraph 5.1). The delivery equipment is : QUANTITY EQUIPMENT 2 Set of stop logs with guides Lifting beam Stop log storage rack Travelling band screen with wash water device 4.2. LIST OF APPLICABLE DOCUMENTS “The following list indicate the corresponding reference of all document quoted in the Operation Manual. ‘Customer Nber | Beaudrey Nber Description E 102290 Pal Diagram Unit NTA 7979-22 | Maintenance manual NTA 7968 | Logic diagram NTA7977-2 | Commissioning procedure Please refer to last revision of documents. of present document E- BEAUDREY & Tis conan hat can nt FOSS in ey pat OAD TS WN eT. IF IN DOUBT ASK Page: 14 3.21-402.1 MAIN DATA 2.41 GENERAL (©8206-NTA7979-21-ON-DEG-revo Operation Manual 2. DESCRIPTION EQUIPMENT DATA Fluid Sea water High water level +0.64m Low water level 117m Service deck level +355 m @ J invert ver 7.08 m Flow rate - Nominal 29000 mh - Maximal 35 400 m"/h 21.2 BAR SCREEN EQUIPMENT DATA Quantity Aperture dimensions ~ Height 6.00 m - Wiath 5.00m Screen useful dimensions eo. Height 5.70m - Width 230m Screen inclination 10° Bar section 40x8mm Bar spacing 50 mm Loss of head clean screen 0.08 mwc Structural design loss of head 1.00 mWe "B-BEAUDREY & Gi everson this dovirsat a can ol be edieed ia any punt wikou is wien consent IF IN DOUBT ASK Page: 12 3.21-41(C8206-NTA7979-21-OM-DEG-revO ED) « seevace Operation Manual 21.8 TRASH RAKE EQUIPMENT DATA Type DS Mobile Rake travelling speed - downward 4 mimin. = upward 4 m/min Mobile platform travelling speed 4mimin 2.1.4 HOIST DRIVING UNIT 21.41 Gear-reducer 2.1.4.1.1 First gear reducer EQUIPMENT DATA Manufacturer ROSSI Type M2180 UC2A B21 112 N45 Reduction ratio 10.6 Output speed 182 rpm Dimensions APPENDIX + Weight 36 kg 2.1.4.1.2 Second gear reducer EQUIPMENT DATA Manufacturer ROSS! Type MV 161 UO2A 1921485 Reduotion ratio 1732 Output speed 4,42 rpm Dimensions APPENDIX 1 Weight 190 kg "EIBEAUDREY & Che sacives a oghtsom i dctrtnt il can ol be reproduced in aay pan >aoUT Is Wien Com IFIN DOUBT ASK Page : 13 3.21-42EB enna 2.4.4.2 Self braking motor (©8206-NTA7979-21-OM-DEG-revo Operation Manual EQUIPMENT DATA Manufacturer VEM Type B21R 112M4 Fé Power 4kw ‘Synchronous speeds (60 Hz) 1400 rpm Electrical supply 400 V - 50 Hz - 3 phases Enclosure IP 56 Insulation class F Standard assembly 1112. BS Coiling 1 Motor’s brake = Electrical supply 230 V-~50 Hz 1 phase ~ Brake torque 63 Nm Dimensions APPENDIX 1 Weight 42Kg 24.4.3 Torque limit switch EQUIPMENT DATA Manufacturer BEAUDREY Type ct Calibration 150 daNm Quantity 1 Dimensions APPENDIX 22 oe 2.1.5 HOIST CABLE ©8206-NTA7979-21-OM-DEG-rovo Operation Manual EQUIPMENT DATA Manufacturer CORDERIE CLEMENT Quantity 2.(1 right +1 lett) Diameter 12mm Length 16.252 Composition 7x19 (7twists and 19 wires) Wire diameter 0.5 mm Breaking load 3660 kg 2.1.8 TRAVEL CAR DRIVING UNIT 2.1.6.1 Gear-reducer EQUIPMENT DATA Manufacturer BONFIGLIOLI Type WF e@/150~300P Reduction ratio 4/300 Output speed 4.8 1pm Dimensions APPENDIX 3 Weight 75 kg 2.1.62 Electrical motor EQUIPMENT DATA Manufacturer ABB Type M2QA 100 LA4 Power 2.2kW Synchronous speeds (50 Hz) 1400 rpm Electrical supply 400 V - 50 Hz - 3 phases Enclosure IP 55 Insulation class F Standard assembly T100 BS Coiling 1 Dimensions APPENDIX 3 Weight 34 kg FIN DOUBT ASK Page :15 3.21-44€8206-NTA7079-21-OM-DEG-revo Operation Manual 2.1.7 GABLE WINDING DEVICE DRIVING UNIT EQUIPMENT DATA Manufacturer DELACHAUX Type BNA 08 1VNO M511 /3TPO5O Protection P55 Electrical motor = supplier Leroy Somer © ~ type ~ power 0.37 KW + Electrical supply 400 V - 50 Hz - 3 phases + protection IPSS ~ Insulation F + Heater resistance supply Not applicable Travelling speed 4 m/min Dimensions. APPENDIX 4 2.1.8 HEAD-LOSS DETECTION DEVICES EQUIPMENT DATA Manufacturer ENDRESS-HAUSER Type Ultrasonic Probe type FDUS1-AG1A ‘Quantity of probes two per fitter Transducer type FMU 862-RIA1AT ‘Quantity of transducer 1 Electrical supply 220 V - 50 Hz - 1 phase Protection P65 Head loss level - ist Loss of head (start cycle) 0.15 mwC - 2nd Loss of head (alarm) 0.25 mW. Dimensions APPENDIX 5 "EDBEAUDREY & Cie eouiveallrighs on Wis docuenl Ui coe tol Ue 1e}s0d0e0d a pal Wie IF IN DOUBT ASK Page 6 3.21-4568206-NTA7972.21-OM-DEG-revt E. BEAUDREY & Cle €D Operation Manual 2.1.9 CATHODIC PROTECTION * Refer to Cathodic Protection System. 2.1.10 WASH-WATER DEVICE Not applicable: elton Rr oriten cso IF IN DOUBT ASK Page: 17 3.21-46(C8206-NTA7979-21-OM-DEG-rev0 € E. BEAUDREY & Cie Operation Manual 22 GENERAL DESCRIPTION Refer to Trash rake assembly drawing paragraph 5.1. 22,1 MAIN SUB-ASSEMBLIES. ‘The mobile trash rake equipment mainly consist of : - Aset of fixed parts : « Abar screen, + Aset of sactiicial anodes, + Aset of guides, + Aset of under carriage rails for travel car. - Arake and troliey assembly, = Amobile platform including = » Arake tilting device, + Aset of limit switches, + An hoist unit, + Atravel driving unit, + Atrash collecting device, - Ahead-loss detection device, = One control cabinet. 2.2.2 DESCRIPTION OF MAIN SUB-ASSEMBLIES 2.2.24 Bar soreen ‘The bar screen is composed of two elements boited on support cross beam which are embedded in the conerete work. 2.2.2.2 Rake and trolley The rake and trolley assembly is composed of : - One fabricated trolley is fitted with 2 rakes bearings and 2 buffers at bottom part. - One fabricated rake with builtin water scoop for the debris flushing, a comb and an hoist rope fixation device. The trolley is guided by two rails and itis lifted by the hoist through the rake. ‘The rake rotates around its both swivels when it comes in a high or in a low position. Atrash deflector flap assembly allows the evacuation of the trash debris into the gutter. 2.22.3 Hoist unit The trolley and the rake assembly travel by means of a hoist inoluding one selt-braking motor, flanged to a gear-reducer driving a cable drum keyed on its output shaft. A torque atm and a torque limit switch prevent the gear-reducer from rotating, ‘The trolley hangs from two cables, The cables wind around the cable drum. The drum bearings are fixed on the upper part of the guides. ‘A special ending allows the adjustment of the cable's length 90 as to horizontally set the rake and the trolley. A special device allows the tensioning of the lifting cables. The TE BEAGOREY & Cie vaseroer al ight em thie dgoarant hat can pte eproend I any pat Wiloat iu ie Conse IF IN DOUBT ASK(CB206-NTA7979-21-OM-DEG-rev0 E. BEAUDREY & Cio € 5 Operation Manual switches deliver an alarm when one of both cables breaks or slackens. In the meantime, the motor of the driving unit is tripped down, In the Jow position, the down-travelling trolley is stopped on its butters before actuation of low low limit switch, In the high position, the up-travelling trolley is stopped by top limit switch. The rake is put in vertical position by a tilting device (iting wheel). 2.2.2.4 Tilting device The titing beam is bolted on the trolley's guides upper part. Its two rollers control the rake tilting operation in high position, 2.2.2.8 Trash-collecting device The trash-collecting device include : ~ an articulated flap with shock-absorbers ; = one trash deflector bolted on the frame to guides the trashes towards the debris trough. 2.2.2.6 Mobile platform ‘The mobile platform includes: ~ a structure with the *anti-reversing® clamps, the ladders, the hand-reiling and the grating for personnel safoty ; - an under-carriage ; ~ abrake-motor flanged on the hollow shatt gear-reducer which is directly keyed on one. ofthe axles ; = acable winder fitted with an electric return motor, a heating resistor (50 W) for the collector ring heating and an electric power cable ; : = acontrol stand and the electrical switchgear cabinet at deck level ; 2.2.2.7 Limit switches They are as follows : = One "top limit switch located on the top part of guide, stops the upwards travet of the trolley, = One "low limit switch" located on the end of the hoist drum shaft, detects the “iow area”, ~ One “low low limit switch" located on the end of the hoist drum shatt, detects the "low low position” if itis actuated within "low area’ (when low limit switch is already actuated), At this "low low position’, hoist is stopped and upward travel is actuated after a pre-set time lag, ~" Two “slack rope switches" located on the driving unit they are activated in case of hoist ropes slacking. They stop the driving unit unless the trolley is in "low area", = One "torque limit switch" located on the driving unit is activated when the upwards travel of the trolley is not stopped by the high limit switch or when the motor is overloaded during the up-travel, = One “raking position” limit switch located on the top of guide at deck level. + Head loss detector with probes upward and downward the trash rake. gwen coset(CB206-NTA7979-21-OM-DEG-revt 2.2.3 WASH-WATER SUPPLY DEVICE Not applicable. 2.2.4 CATHODIC PROTECTION Refer to Cathodic Protection System. 2.2.5 TRASH BASKET ‘The trash basket consists of a fabricated container made of stainless steel perforated sheet and frame. 'E/BEAUDREY 2 Gi reserves ll igi on bin documert ht can aor be reproduerd tpt Dou ls Wit Gono, IF IN DOUBT ASK . Page : 20 3.21-49€8206-NTA7979-21-OM-DEG-rev0 EB sounnvace Operation Manual 22,6 ASSOCIATED COMPONENTS 2.2.6.1 Electrical contro! equipment Refer to control panel outline drawing paragraph 1.2, The trash rake is controlled : + From travelling band screen control panel (display of head loss only), + from the control cabinet. 2.2.6.1.1 Electrical contro! cabinet This cabinet communicetes with : the hoist overtorque limit device, the hoist driving unit, the travel driving unit, the limit switches. ‘The front panel is fitted with operation and alarm signalling (lights), with selector switch and push button. The front panel is composed of : 1) One common Lart: = one power on general switch, + one system Ov- OFF selector switch, + one Lamps TEST push-button, + one RESET push-button, + one LicHTine selector switch for external working lights. + one EMERGENCY SToP push-button. 2) o fic control part + one AuTo— SToP- Manu three positions selector switch, «one START CYCLE push button, + one UPwaros push button, + One Downwaros push-button, 3) One specific contyo! part for travel car + one travel car circuit ON- OFF selector switch, + one FOREWARD AUTO 0 ~ FOREWARD— BACKWARD selector switch, + one ON jog push button. 4) One display common part : + One Power ONlight. 5) IFIN DOUBT ASK Page: 21 3.21-50(C8206-NTA7979-21-OM-DEG-rev0 ( E. BEAUDREY & Cl EB BEAU ° Operation Manual One display specific part for trash rake ; + three signalling lights. > Trash rake stop RAKING STOPPED, > Upwards travel UP, > Downwards travel Down, 6) One display specific part for travel car + one signalling fight > Travel car ON TRAVELLING. 7) Qne failure specific display part ; «three failure lights for trash rake > Hoist unit ToRaue Limi, > Hoist driving unit Motor Fault Hoist OVERLOAD, > Hoist cable Stack ROPE, + two failure lights for travel platform > Travel driving unit Motor Fauit OveRLOAD TRAVEL, > Fault of raking SaFery Position. 2.2.6.2 Security and auxiliary components 2.2.6.2.1 Holst Motor gear-reducer ‘The gear-reducer is supplied with a torque-imiting device (torque limit switch} In case of overtorque detection, the torque limit cevice switch the trash rake off. A thermal magnetic manuai starter located in the power supply cabinet protects the motor. 2.2.6.2.2 Travel car motor gear reducer A thermal magnetic manual starter located in the power supply cabinet protects the motor. 2.2.6.2.3 Head-loss detection device The trash rake is equipped with a head-loss detection device. ‘Two sensors are installed, one on up-stream and the other one down-stream. ‘The transmitter Is located in the travelling band screen control cabinet. 2.2.6.2.4 Rake and Trolley A slack rope detection device stop the hoist’s motor when one of the cables break or slake. The switches are located on each side of the upper guides. 2.2.6.2.5 Travel car A set of limit switches located on the mobile platform is used to detected the raking position and the end of station. pions doc aca an be nero IF IN DOUBT ASK Page : 22 3.21-51(©8206.NTAT979-21-OM-DEG-revo E. BEAUDREY & Cie € 5 Operation Manual 2.2.6,2,6 Electrical control cabinet The electrical control cabinet is equipped with heating resistance and cooling fan control by means of thermostat, TBEAUDREY & Cle wserres ah fcamam al can fale roproduere IF IN DOUBT ASK Page : 23 par wihow is witen cons 3.21-52©8206-NTA7979-21-OM-DEG-rev0 € B E- BEAUDREY & Cle Operation Manual 3. OPERATION 3.1 GENERAL The trash rake is used to remove floating debris, rubbish and other materials from the intake bar screen. 3.2 FIRST START-UP AND START UP AFTER INTERVENTION 3.2.1 FIRST START-UP - Refer to last revision of Commissioning procedure document (refer to paragraph 1,2). 3.2.2 START-UP AFTER INTERVENTION - Check that the maintenance operations of the trash rake have been carried out. @ —.- Check the cieantiness of the channel. Use a diver if necessary to the check-up in water. f AAS sarery warwine Jn case of diver intervention, it is IMPERATIVE to stop and secure the equipment. ~ Verify that no tool has been left behind on the working areas around the trash rake. ~ Check that the protective coating Is in a good condition. ~ Check that the lifting cables are tight, Verify the lifting cable's fastening devices, ~ Verify that the trolley is in the top position and that the rake Is in vertical position, + Check that the fuse switches and the thermal relays of the motors are switched on. ~ Check that the clroutts are available to allow the trash rake’s. - For the other operations, refer to paragraph 3.3.1. 'E BEAUDREY & Cievesrvsti igh on hs dnounea a can ot be opodaced say par >a he writen omer iF IN DOUBT ASK Page : 24 3.21-53(C8206-NTAT979-21-OM-DEG-rev0 ED ccnonersce Operation Manual 3.3. NORMAL OPERATION ‘The trash rake operates from the control cabinet. 3.3.1 START-UP OPERATIONS ATTENTION Never start the CW pump without operates first the trash rake manually to reduce the trash gathered to intake pit during the plant shut down. = Check that the contro! cabinet is supplied. - Check the head loss detection device is ready to operate. - Check the contro! pane'’s lights by pushing on the Lamps Tes7 push-button. All lamps must light on. = On contro! cabinet : + Set the system and travel selector switches on On position. + Set the trash rake mode selector switch on Agro position. + Set the travel mode selector switch on FORWARD AUTO position. + Stait the trash rake for one cycle (refer to paragraph 0). ~ Check the following elements : + Travel driving unit (neither abnormal noises nor vibrations), + Hoist driving unit (neither abnormal noises nor vibrations), + The cable reel (neither abnormal noises nor vibrations), + The rake and trolley position step by step. 3.3.2 AUTOMATIC MODE This is the normal operating mode, obtained when : «Set the trash rake mode selector switch on AUTO position. + Set the travel mode selector switch on FORWARD AUTO position. On automatic mode, there are two different orders to operate : ~ the rake start cycle push-button, = the travel on push. ‘As a head loss level is detected and displayed on the travelling band screen control cabinet perform the following operations : Refer to drawings NA 13541 & 14114 in paragraph 5.2. = The operator presses the travel Ow push button. > the car travels (Forward or backward) as long as the operator presses the jog button, and stop to the next raking position. ~ The operator lock the travel car. = The operator presses the rake CyoLe push button, > The cycle must start from the “high limit switch” to be sure that the rake is in top position, > The hoist motor starts and the trolley goes down, TE DEAUUREY & Ciovesrves a ghee documen Tal au not be prodvord oan pa Wiaat swe COO IF IN DOUBT ASK Page : 28 3.21-54: (€8206-NTA7970-21-0M-DEG-rev0 € 5 E. BEAUDREY & Cie Operation Manuai v “The low area is detected by the “low limit switch” and will be confirmed by the “low low limit switch", The trolley goes down until it rests on the rake stops, The holst unit runs until actuation of the “low low limit switch” in the low area, as the rake swings to engage the bar rake, After a few seconds the trolley goes up, As the trolley is going up, the wiser strikes the top stops and takes sweeps. ‘The trash is thus unloaded. > The “high limit switch" fs actuated when the trolley and the rake have reached their storage position, > The actuation of the high limit switch stops the hoist motor. 3.3.2.1 Head-loss level Not applicable. 3.3.2.2 Timer Not applicable. 3.3.2.3 Start cycle push-button ‘This push-button is use to check the right operation of the equipment in automatic mode or to operate a single cycle when necessary. When the Starr Cycle push-button Is pressed (impulsion), the trash rake is set into operation. 3.3.2.4 Head loss detection device fault Not applicable, vv vv 3.3.3 MANUAL MODE 3.3.3.4 Trash rake ‘This operating mode is obtained when : - The trash rake mode selector switch is on MANU. position. This operating mode is only used for adjustment, maintenance or revision of the trash rake. ‘The trash rake travels as long as the operator presses one of the two push buttons actuates the push button Up or Down. ATTENTION All automatism are suppressed in this mode, but alanns remain operational. At the end of the manual sequence, it is mandatory to set the rake in the high limit switch position in order to allow automatic operation. 'EBEAUDREY & Ge rvacver al igus on is docoment a cah ht be eproduced in iy pn witout He Walon GmaenL, IF IN DOUBT ASK Page : 26 3.21-55(€8206-NTA7979-21-OM-DEG-16v0 E, BEAUDREY & Cle €@ Operation Manual 3.3.3.2 Travel car ‘This operating mode is obtained when : - The travel mode selector switch is on FORWARD OR BACKWARD. position. This operating mode is only used for adjustment, maintenance or revision of the travel car. ‘The mobile platform travels as long as the operator presses on the ON push button. ATTENTION All automatism are suppressed in this mode, but alarms remain available 3.4 CHECKING INSTRUCTIONS IN NORMAL CONDITIONS 34,1 AUTOMATIC MODE = Make sure of the vertical position of the rake being in the upper part of the guides, - Make sure of the rake’s horizontal position during the upward travel and check the titted position when resting in the top position, ~ Check that lifting cables are always tight. = Check that electrical cable is always tight. - Ensure there are neither abnormal noises nor vibrations. 3.4.2 MANUAL MODE ~ Make sure of the rake’s vertical position when itis resting at the top of the guides, = Make sure from time to time, of the rake’s position during the upward travel, ~ Check that the cables are always tight. ~ Ensure there are neither abnormal noises nor vibrations. 3,8 SHUT-DOWN OPERATIONS The following operations are performed to check the trash rake, without intervening on its components. - Before shutting down the trash rake, make sure that the relative pumps can be tripped down, = The rake must be in the top resting position, ~ Set the electrical controt cabinet mode selector switch on the OFF position. = Switch off the fuse switches of the hoist motor, - For further indications refer to maintenance Manual, "EIBEAUDREY & Cle recerve all ight on ls docuat Wt can Rt be 1produee In oy par without Hs waa onset IF IN DOUBT ASK Pago: 27 3.21-56€8206-NTA7979-21-OM-DEG-rev0 &. BEAUDREY & Ch 5) ° Operation Manual 4, INCIDENTS, CAUSES AND REMEDIES A SAFETY WARNING Under no circumstances are divers to be allowed to work until ail wedged equipment has been safely propped up against invert . 4.1 INSTRUCTIONS IN CASE OF ALARM SIGNALLING All alarms are treated through an alarm sequence and two push-buttons : = One RESET push-button one the MCP panel), - One La TEs push-button for the MCP. ‘When pressing the Lamp TEST push-button, all lights on the front panel, if not damaged, should light on, As the defect disappears (differential pressure, fault, ..., the reset push-buttons (MCP) has to be pressed to allow further cycles of the trash rake to be performed. Alarms relative alarms to the trash rake are shown on : > the trash rake control panel, > the travelling band screen control panel (for head loss only). On the control panel each alarm is coupled with its corresponding priority (P1 or P2) ones : - High priority = P1 operator should investigate immediately - Intermediate priority = P2 operator should investigate within 2 hours. Priority Fault Consequence P2__ [Hoist OveRLoap (Hoist motor faut) | the trash rake is stopped P2__| TRAVEL OVERLOAD (Travel motor faut) | the travel car is stopped P2__|Torave Liar (Hoist overtorque) _| the trash rake is stopped P2__|Suack Rore the trash rake Is stopped P1__ [SAFETY Posmion (raking position) _| Raking cyele is not availabie. P1__[Hich LeveL (OP level 2) Continuous operation P1__| EMERGENCY stop Machine is stopped P1__|No power supplied at the machine _|Complete system is stopped * if “slack rope” faut occurs during a downward travel, the hoist motor will stop and starts in the opposite direction to re-store the rake in top postion. If rope slack persists during upward travel, the holst motor f stopped, it means that the rape is broken, .BEAUDREY & Gs rere al sighs on is document tat on pot be pod AF IN DOUBT ASK5.1 GENERAL DRAWING (€8206-NTA7979-21-OM-DEG-tevo Operation Manual 5. DRAWINGS ‘The following drawings are delivery separately. Drawing N° Customer Nber | BDY Title E 102418 Intake screening equipment General arrangement E 102442 Trash rake assembly “EIBEAUDNEY A Ce rscrcs nigh on Dis Grcumont ta sen ro be roprodiced any For WoT HS We ComEEN IFIN DOUBT ASK Page : 29 3.21-885.2. OPERATION DRAWING (©8206-NTA7979-21-OM-DEG-revo Operation Manual Drawing Title NA13541__| Trash rake operation NA14114 | Travel car operation@& NA13641 “EL REAUDREY & Ci 8. ASS. Drawing Nr./PlanN® Rev. 1700 NA 13544 A TE BEAUDREY & Cle veeerves al gis on his document hat can nol be reproduced in any part wthout Ks writen consent. Ce document appartient &E. BEAUDREY & Cie. Toute roxoaucton, méme parele ne peut re ale sans son consertement or IF IN DOUBT ASK 3.21-60NAIA114 E.BEAUDREY & Cle e a ot 1 Travel the mobile towards the bar screen nM 2 Stop the mobile in front the target and tock — ee Ht : a 1 e cP ts 3 Perform the raking operation 4 Unlock the mobile and travel Saino se S. ASS. Drawing Nr. / Plan N° Rev. 1700 NA 14114 A E. BEAUDREY & Cla osorvas all gts on vs document that an nol be repoduoed in ay oad without Ks wrtten const ‘Ce decument appatint 2, BEAUCREY & Cle. Toute rapreduction, méms parle ne peu ie fa sans 6en censanterert rt. IF IN DOUBT ASK 3.21-61Intentionally Biank 3.21-62‘C8206-NTA7979-21-OM-DEG-rev0 APPENDIX 1 HOIST MOTOR GEAR REDUCER TS DEAUDREY & Cr vesrves U ie on ie dsl can at eprodnord sy pr won Fa wen Fone IF IN DOUBT ASK 3.21-63Intentionally Blank 3.21-643.21-65 3 we aes sss na sot — 08 —M ween: sm ee ana 9 om ono Oda. PRES FR EB 98 —v TPSRWIESS WS OLEH x B-VEOSE IN SEXCI-— 9/6 —— v1 ov0.9 ova com mz Sra uoHen en svg mn aac te ae ] —-E EI ESS S- seeded ey (| i) ip SS min. LUD) - 7 8 t y T Se Ga-T099 Win) wwe — = oe 1@i—wo— = vereisseatomncam, cs — 09 wn Son ecw ea us Em A 9K 'SA BOW sas ad USO EAM) CumMeyyoR>HOW SYD .7/E CURES BB Od 200 $7 Ban sUORNHSE w BIEN ~ ree vea8 o we N wSo 10 fan a ra Oe = a ET aaa ana on wil pes a8 Uomtnop a ee wa Hd ce Ee HOLINGRDION 50H ED) “Sate p algae © open oe gmat sou recur oa menoutean ous ISSR see | creme omar SS = ‘Tuna Bsom 9 x URE Ay;UONE SOIDFS 104 sy sehyO UBAT er, [Z| SES VZON LOL A WW AW “1p saibBow Qiwonb ©} oop 010g Di Odep BOA Ht -| “ml al 86/60/10 vv0)anon nS 3 eon ong \— a —r0 aKa ees Bn SS — 99 2G) — v1 — YE8- V6 BN SDOH— 9/S0.— 70 29— 27K BH Boao mn co TSNEAD soe I ee ee SELES — eo — ons — ra omen eee Sen Bas enna = “ll i ; i RL RIO ER. NEEM Sa 59 — sere (aes) OYE Oe — 91 — rove ES a = sam ereties_ | rem 9, fensoon— BEIGE = BEES uy arcs nH SERBS a aon — seme cee Pan as ae 200 ST aan ame P opr - 190 ava aA ory aBNDSSaIdSS UH ORD Ay — Hitunuon sot (3) Lely "a O6CS VZIN 08 IZ YW EO/LOM} We 3.21-66(©8206-NTA7979-21-OMDEG-rev0 € B ©. BEAUDREY & Cle Operation Manuat APPENDIX 2 TORQUE LIMIT SWITCH TE BEADDREY & Cle earn alight on tl omen Daten el be rprodvonn sy paw oal ie wien oan IF IN DOUBT ASK 3.21-67Intentionally Blank 3.21-68€ B E, BEAUDREY & Cio Instruction Manual DYNAMOMETRIC SWITCH Refer to drawing NA 12185, DESCRIPTION This instrument is designed to protect reduction gear against overloads during normal operation and against accidental jamming. It is installed at the level of the torque arm and can function under compression or traction or both, OPERATING PRINCIPLE An elastic element is housed in a cylinder and, under stress, acts on two micro contacts which have been pre-set on fixed values predetermined by the user. The original design of the sensitive element permits, with the same space requirements and the same fastening procedure, obtention of the following functions: ~ detection of compression, ~ detection of traction, ~- detection of compression and traction. NOTE: The contacts are normally closed. WARNING Painting forbidden CHARACTERISTICS AND DESCRIPTION Construction: Stainless steel, impervious to infiltration by water, fastened by 2 tapped holes, M20 diameter. Foolproof electric set point S. At the request of the user, the Manufacturer can set the contact point Important It is not possible for the Customer to set it after delivery. For types traction or compression: Setting is possible on all values between 60 and 2200 daN. For type traction and compression: Each contact involved by the direction of the stress applied can be set independently 50 % of maximum toad. Accuracy and reliability: + 5 % of the setting. Resetting range: - 10 % of the setting. Admissible overload without alteration of the setting value: 100 % of this value. Breaking strength: > 3600 daN. TELBEAUDREY & Ch ronrveralldghison Tarn a ca at bs aro duced ay Pet wT TA WAN OSE 3.21-69oe Instruction Manual ELECTRICAL CHARACTERISTICS Electrical strength at sea level: 1500 V between outputs and mass, 500 V between outputs. Micro switches: type A.CEM. Common point change over switch. Service temperature: - 40°C to + 85°C. NOTE: Cabling of contacts are on the plate fixed inside the torque limiter connection box cover. Nominal voltage Electrical clrcult Electrical service life Resistance Induction 30V= 415A 075A 125V~ 3.0A 150A 100 000 cycles 250 V ~ 15A 1.00 TB DEAUDREY & Cie reserve al iis ov Wa ocaeat at oan nt be Toproauad Ip ny pat wnat lo wien cae 321-70Instruction Manual TERMINAL BLOCK FOR TORQUE LIMITER BLUE D, ©) WHITE o RED ELLOW &| GREEN BLACK GREY GREEN GREY BLACK 6 4 ——— GREEN 5 rl YELLOW & GREEN For normally close contact signal + Add a wire link in terminal box between the blue (1) and the black (6) wires. * Add a wire link between the red (3) and the grey (4) wires. + Connect fo your contro! panel the white (2) and the green (6) wires. For normally open contact signal © Add a wire link in terminal box between the biue (1) and the black (6) wires. ‘© Add a wire link between the red (3) and the grey (4) wires. * Connect to your control panel the blue (1) and the red (3) wires. TE DEAUDREY & Cio recor al igus on Us docunen Tat ann be opodaizt hn any Far witou fa rien cone 3.21-71NA12185 . BEAUDREY & Cle MOBILE SIDE PARTIE MOBILE: STATIONARY SIDE, PARTIE FIXE 50 on fats / S0sur plat Independent orientation of outlet af cablo Orientation indépendante de la sortio du cable M20 8, ASS. Drawing Nr./PlanN° Rev. 2005 NA 12185, B 'E. BEAUDREY & Gle reserves all gis on he document tat can not be reproduced In any par without is wien conser. ‘Ce Gocumert apparten &E. BEAUDAEY & Cle. Toute epcoduction, mba patele ne peut ére fale sans son consentement rt Page:3 3.21-72(©8206-NTA7978-21-OM-DEG-rev0 E. 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Uo epoduced in ay por wit he wetn Coma, IF IN DOUBT ASK 3.21-89Intentionally Blank 3.21-90ieee Prosonic FMU 860...862 Ultrasonic Measurement Operating Instructions Endress +Hauser EH; ‘The Power of Know How oe 3.21-91Intentionally Blank 3.21-92Prosonic FMU 860...862 ‘Table of Contents Table of Contents 8 Measuring Point Entries... 2... . a Software-His! 4 “my 1 Refreshing Information on the Measuring Point . 77, Notes on Safety 5 | 82. Leoieng the Matix Sone te TF Safety Conventions and Symbols 6 9 Diagnosis and Trouble-Shooting .... 79 4 Introduction. 6. ee 7 3h BeypesotFa arms and wamngs . - = 79 iA Features . © | 83. Suppression interference Signals | || | ad 12 MoasutingSyetom 222212118 | Be Seeutaton Ps 4.3 Measuring Principle» vee 11 | 38, ererga the Roser FNL oraenes” «87 2.6 Repairs: . 7 2 Installation ©. ee 13 2.4 Mounting the Presonio FM 18° | 10 summary: 22 Electrical Connection «1 ee 7 10 ‘of All Calibration Modes... 69 23. Tecirical Data 2 11 PROFIBUS-DP-Interface ©... 1... OF 3 Controls... eee ee y 5.1 Preaoris Operating Matic za | 114 Siapse a 32 Dieplay and Contot: Prosonie FMU |e eos teminstion a 33. Operation via a Doves dete 7 Univorcal HART Communicator OXR 275 at 114 Devin dbs andy es 13 34 Operation with Commanint 82 | is Acyete dataexchange 2.2) 07 4 Level, Difference, Average Value 4 At BacieSetings — ‘Appendix A: Weirs and Flumes .. . . . an 4.2 Basia Aductnont: EmptyiFullAduciment . 37 43° Unearzaion . . . Dhow ‘Appendix B: Appl Parameter VOH3 aA Linearization for Vessels of Any Shape 42, B Heation eter wa 4.5. LevalDiference Measurement er e Screen Cont: rating Matin 188 4.6 Level Measurement with Calculation of the Operating ‘Average Velie .. 48 Matrix Prosonic FMU 860... 2... . 126 B Mow... 2. ee ee 49 5.1 BaskoSotings ..48 $4 Basle etnge £ Matrix Prosomic FMUS6T...... . . 127 5.3 Setting the Ttalizee low 5.4 Flow Measuremert end Back Water Alérm (Only alter Selecting Operating Moce Matrix Prosonic FMU 862... . ~~. . 128 VBHO: 9 »Back Water Afarme) 58 Index soe eee ee 109 6 Analogue Output 2... Bo D RoE . 14 ela Surin Line 86 parating instructions are wien for the 7.2 Relay Function »Alarm Relay~ a ‘software version 2.8/2.4 of the Prosonic trensrritter. 23 Relay Function »Tendency< Version 2.4 is used for devices with a PROFIBUS-DP 74 Relay Function «Counting Pubes - 70 | | version 24 75. Relay Function sTieing Puisese | | Me 78 Relay Function «Back Water Alarrn« % Endress+Hauser 3.21.93,Software History ‘Prosonic FMU 860...862 Software History Universal HART [SW7 [Device and Joevico [OD |Ohanges Remarks Communicator BA Software No. |rovision [revision OXR 278 1.07 [5910 o Ht No upfdownioed 04.99 botween Sw 1.x 1.1/7 [5011 JNo change in fend SW 2.x |B. Jdocumentation possible 1293 (207 bem a F lEionded tunctone (cags aie [eal No changes 09.95, cocumentatlon i22/ [5022 Extended urctions 05.00 231 ass icended functions 1299 4 Endress+Hauser 3.21-94Prosonic FMU 860...862 Notes on Safety Notes on Safety ‘The Prosonic FMU 860.,.862 is an ultrasonic transmitter which, depending on the Approved usage particular version, can be used for the following measurement tasks: + Flowrates in open channels and wairs ‘+ Water levels * Control of rakes andi pumps ‘Levels in silos and tanks: * Determining the volume or mess of contents on silos and tanks ‘The transmitters Prosonic FMU 660, 861, 862 have been designed to operate safaly in accordance with current technical, safely and EU standards. W installed incorrectly or used for applications for which they are rat Intended, nowover, It is possible that application-related cangers may arise, ¢.g, product ovartlow due to incorrect instalation of calibration, For this reason, the instruments must be installed, connected, operate! ‘and maintained accordng to the instructions in this manual: personnel must be authotsed and sultably qualified. The manual must have been read and understood, and the instructions followed. Mocificalions and repairs to the devices are perissible only wien they are expressly approved in the manual. Ifthe device Isto be instatled in an explosion hazardous area, then the specifications in the certificate as well as ail national and local regulations must be observed, Endrose Hauser 3.21-95 ‘Mounting, commissioning, ‘operation Explosion hazardous areasNotes on Safety Prosonic PMU 860,..862 ‘Safety conventions Exploston protection Electrical symbo!s Safety Conventions and Symbols In order fo highlight ealety-relevant or alternative operating procedures in the manual, the following conventions have been used, each indicated by a corresponding icon in the margin. [meaning ioter [A nctrightghis ecions or procedures which if nok performed coecti, may incactly eect operation or may ised fe an incturron ospansa wrioh i nt planned, (Gauttont [Caution highs eaions or procedures which, fot performed correct, may load io Personal nu or neceectunetining othe iiument. Warning! |Avwarring hightghis actions or procedures which, i aot performed corecy, may load > Personel jy, a easy hazard destruction ef th iratumect. Rearing Dovice cortifed for use in explosion hazardous area tee device ras thle sybol emboasedt cn is rar plate It can be insted in an axctesien Inazerdous se, Jéxplosion hazardous area [Syioo usec drawings to indicate avptosion hazerdous areas. J Dares oad in ar wing entving teas wih be desipnaion “xpos hazacans yBa5" mut cantor wih te saled "ype of protectin. [Safe area (non-explosion hazardous ares) [Synod used h cravings to rcicaa, I neoassary.nen-sxposion hazardous areas, | Dovioos located in safe aeas sl requis a ouicata ft outputs un into axpielen azerdove aos. [Mesning |i Peo Direct voitape [Aten owtich o irom which a dest Curent or vatage may be appa! e supp, JAternating vokoge [A terrinal to which orm which an atenaiing (sine-ave) cutent or votage nay be |apetiod a surat. [Grounded torminal [6 grounded termina, which as far 25 the operators concerned, Ie akeady grou by jneans ot an eat grounding system, Protective grounding (earth) terminal [ternal wtion must be connected to earn ground prior making any har connaction to ne squioment. Eqvipctential connection (earth bonding) JA Srmection made tothe plant grouncg system which may be of type e.g. nel sas or Jequpotenal re according te national company oractic. Encress+Hauser 3.21-96Prosonic FMU 860...862 1.2 Measuring System. ‘The meesuring system consists of: the Prosonic transrnitter with a Prosonie sensor, The ‘two-channel version is for differential measurement o: collecting data from incividual messuring points. The certified sensor ensures that the measuring system can be used in explosion hazardous areas. thor instruments can be connected tothe Proscnic transmitter for special applications: + soparata temperature sensor, 6.9. the ulasonic sensor is heated * separato limit switch, ‘Transmitters and their applications Prosonic FMU 860 for continuous level and volumetric measurement of liquids and. solids in tanks and silos, Prosonle FMU 861 for flow measurement in channels and weirs, Progonic FMU 862 the two-channel version for * the maasurement of flow rate or fava with the first channel and level measurement nly with the second channel or + diferential or average measurement, ‘Transmitter versions Oe inte os @ irs + soparate clacronios perana unto cen panel operating astra Pours aremautod ceprigh [Ecos orroviec sept [Mounting the loporating unit be 10 rout pia [Mounting the |separate electronics onl sane h secronce Endress-+Hauser 3.21-97Chapter 1: Introduction Prosonic FMU 660...262 Tab 12 “The code en ho rameplaie stsles the vrai and Contraion, The cod is explained in this tbo. Accessories 40 Prosonic transmitter FMU 86.. © One channel fr level messurement wah ultrasonics 11 One ehannal for fou measurement wilh Utrasonics 2 Two channels fer low andr lvel measurement, dferenial messurerrent Certcates Rr Standard (ron-cetfec) CSA Geracal Pune Housing fr electronios 41 [P.O protactve housing, fer fel mounting and operation 2 Plosdo housing IP 40 for emote operation 7 Mouring pote P 10 for coniral panel ouning and rrncle operon Versions for eperationisleplayitotaicer for flow measurement ‘Keypad in rotactve housinguthesplayfwnout ose rotor FUL ES? Keypad in protective housing ceplayvithtotabser, el for FMU 880 Koypad in prtoctvehousingwth urinated cepayuithcut oie, not for FMU 884 Keypad in prtnetivehouslng/ath Mursnote spayfulth tots, not for FMU 860 ‘Sopareie keypad for contol panelwkh dplayvtnout counter, vihaut RS 485 ‘Soparatekaypod for contol panat wih urinated cplayuitout counor ‘witout RS 485. ‘Separate keypad fr racldwlh display thou! countorvthout RS 495 Separate keypad fot raekvahUminatod eeplaythoulcourtar, ‘our RS 465. ‘Operation and dpi va digtlintexfacs Ret 1 Trae potenitaltoe change-over contacts 2. Phe potato tee change-wer contacts, only wit versions witout RS 485 or PROFIBUS-DP a om @ > ogo He AC 90,192 BORO He AG 3B..55V SO6DHe AG 18.28V SOR He DC 20.30 "wihout interface ‘Seni ntertoco ah HART protoco para seal Ractbus RS 485 intrtace separa eeiael PROFIBUS-DP interface wih HART protaco, witout HART module <—_——— moose a i | r F g + all-weather cover for the protective housing: material: aluminium, blue lacquered {Order No, 818 567-0000); stainless stest 1.4901 (Order No. 919 887-0009), Weight: approx, 1 kg. Mounting screws supplied. ‘Post mounting materia: galvanised steel (for 2 post Order No. 919 586-0000; fot 1" post 918 686-1000); stainless stae! 1.400; (for 2" post Order No. 919 568-0001; for 1* post: 918 586-1001), Weight: approx. 1 kg, Mounting scrawa and nts supplied. + HART Communicator DXF. 275, Handheld terminal with intagratad serial intertace for HART protocol (see operating manual BA 139F/00ien). Endress+Heuser 3.21-98Prosonic FMU 860...862 . (Chapter 1: Introduction ‘+ The overvoltage protection and power supply units for sensor he in IP 68 protective housing. Power supply unit (24 V D0) for sensor haaling wit integrated vervolage protection for power supa Power supply 230 V (+15%-20%8), Dimanslons: IP 66 protective housing Order No.: 215095-0000 ‘* Overvoltage pretection unit in IP 68 arotactive housing. Dimensions: IP 68 protective housing. Order No.: 215095-000% ‘* Power supply unit 24 V DC) for censor heating in IP 66 protective housing, Power supply 230 V (+15%/-20%).. Dimensions: IP 66 protective housing. Order Now 15095-0002 1.3 Measuring Principle ‘An ullrasonic emitter (sensor) mounted above the product is elactrcally excited and Ultrasonic measurement directs an uittasonic pulse through the air towards the product. This pulse is reflected ‘back from the surface of the product. The echoes partially reflected are detected by the same sensor, now acting as @ recelver, and converted back into an electrical signal. The time taken between tranemisaion and reception ofthe pulsa—the run time—is ctrectly. proportional to the distance between tha sensor and the product surface. The distance is determined from the velocity of sound ¢ and the run time t by the formula: pao ‘With a velocity of sound (in alr under normal conditions) © = 340 m/s, a run timo of 410.ms corresponds to a transmission path of 8.4 m and thus to a distancs of 4.7 mn. F139 Uhsanismascurng pice Blocking este Avs pousb=a3m “The measurement is independent of + product characteristics such as specific weight, conductivity, viscosity and dlelectie constant. « temperature changes within the tank or basin: The Prosonic FMU compensates for variations in temperature as the integrated sensor for temperature also provides temperature information, Endress+tlauser " 3.21-98