THICKENER Mechanism - Center Pier Type Manual

FOR
DELKOR (SOUTH AMERICA) LTDA.

Galvarino Gallardo 1690
Providencia, Santiago, Chile
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
www.delkorglobal.com
THICKENER MECHANISM INSTALLATION PROCEDURE:
CENTRAL PIER TYPE
GENERAL:
1. The contents of this manual which includes drawings, installation instructions etc., shall be
the confidential property of Delkor and shall not be reproduced or made public.
2. Mechanism components would have been supplied in multiple parts depending on

dimensions due to transportation restrictions.
3. Components parts need to be welded or bolted depending on design considered.
4. Necessary erection equipment/tools shall be provided by client.
5. Scope of supply and Installation shall be as per purchase order or any further amendments.
6. All safety precautions should be taken care while welding at site.
7. Drive is supplied as a completely assembled single unit except for powerpack.
8. Gearboxes and hydraulic powerpack are supplied without filling lubricant.
9. Drive and mechanism must rotate in the same direction as shown in GA drawing.
10. Mechanism generally consists of the following items.
Drive unit including hydraulic motors , gearboxes, hydraulic cylinders, drive frame, Tri-
column, hydraulic piping etc.,
Bridge extensions with peripheral gratings and handrails
Bridge with gratings and handrails
2 Long rake arms
2 short rake arms
Inclined tie rods
Horizontal tie rods
Underflow discharge cone scrapers (Trench scrapers) in parts.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Feedwell
With or Without Auto-dilution V-Notch plate.
With or Without Deflector plate
Feed drop box
Feed pipe
Flocculent piping
Hydraulic powerpack
Control panel
Hydraulic piping/hoses
Electrical wires
Gearbox oil
Hydraulic powerpack oil
Automatic Grease lubrication unit for Ring Gear & pinion lubrication. ( if ordered)
Level Sensor for mechanism Lift/Lower travel control.
Mud level sensor (Interface level instrument) - If ordered
Flocculent inline mixer If ordered
11. General checks :
Dimensional check
Level check
Alignment
Plumb check
Tightening bolts to correct torques
Butting surfaces are smooth and straight.
Foundation/Anchor (Hold down) bolts are correct in diameter, projections and
orientations
Surface finish
Painting

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
PRE-INSTALLATION INSTRUCTIONS:
(FOR CLIENT SUPPLIED METALLIC TANKS/CONCRETE TANKS)
Following should have been checked by client before taking up Delkor mechanism components
for installation.
1. Identification of True centre of equipment.
2. Circularity of tank for eccentricity. Eccentricity should be within allowable limits.
3. Tank assembly is complete and anchored properly with relevant bolts.
4. Tank bottom floor surface angles are maintained as per delkor drawing.
5. Bridge mounting holes are matching per Bridge. Check for holes diameter, pitch and surface
levels.
6. Tank walls are straight and all segments are welded in a staggered manner.
7. Tank dimensions per Delkor drawing.
8. Center pier dimensions per delkor drawing. (If applicable)
9. Launder dimensions and orientation of overflow pipe per Layout drawing.
10. V-notch plates are fixed.
11. Underflow cone or trench per drawing and orientation of pipes.
PRE CHECKS REQUIRED:
1. Ensure all parts required are received before accepting shipment

Note:
It must have been notified to Delkor for any missing items immediately after receipt of shipment.
Packing list may be referred to.
2. Ensure the supplied relevant components including fasteners are placed safely and protected
from transit or storage damages.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
3. It is preferred to pre-check mating components holes for any mismatches.
4. Ensure all relevant & correct size and grade of fasteners are available at Installation place.
5. Installation Instruction sheets/Manual must be at the erection place.
6. Ensure the inaccessible surfaces of components are painted before installation.
7. For transportation purpose, some parts will be provided with shipping ties. These shipping
ties should not be removed till the installation stage.
8. If installation is not immediately done after shipment, components shall be kept in protected
place in order to prevent physical damage or corrosion of components.
9. Identification (Mark up) tags shall be in place till installation stage. If mark ups are done using
paint, ensure that these are not damaged during shipment/storage.
10. Ensure all erection hoists/ tools are adequate capacity for installation.
11. When lifting components, use rubber covers/pads to prevent damage to surfaces.(wherever
possible)
12. Ensure tank & support structure is complete in all respects and is ready for mechanism
installation.
13. Ensure columns are installed on proper foundation, Levels are maintained and Hold down
bolts are per drawing.(If bridge is supported on external columns)
14. Ensure Center pier, Torque cage, center pier interface and Tri-column are in place and are
properly secured.
15. All sign boards like CAUTION, WARNING, POWER, DANGER etc., & also NAMEPLATE
shall be protected even after installation.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
INSTALLATION INSTRUCTIONS:
1. Assemble all parts of bridge extension including top beam on floor & Lift complete assembly
onto center of thickener as shown in attached photograph. Place it on Center pier/Tri-
column top at the center of thickener and bolt to tri-column top.
2. Assemble bridge segments on floor.

Note:
Use bottom blocks to maintain camber for bridge. Bolt bridge segments after ensuring camber.
If Feed pipe is to be located inside the bridge truss, Insert it now and bolt it to bridge.
3. Lift it on top of thickener tank and outer end on tank wall brackets/External columns.
4. Align the bridge properly & Bolt inner end of bridge to bridge extension truss and bolt up
the outer end using appropriate bolts. ( Anchor/Hold down bolts when column is
constructed out of concrete)
5. Now place gratings on the bridge and bridge extension around drive frame and bolt them.
Note Gratings should not foul with drive frame. (Meanwhile ensure gap is not affecting safety)
6. Lift Handrails on either side of gratings and bolt to bridge members. Ensure that they are
properly secured. If any projections exist on railings, smoothen them using grinding.
7. Install Toe-guards alongside of handrails.
8. Bolt up rake blades to Rake arms on floor.
9. Lift Inner most segments of Long Rake arms into tank and loosely bolt them to torque cage
at 180 degrees to each other.
Use temporary structure for supporting rake arms to prevent any damage to torque cage/rake arms till
the installation is correct.
10. Now lift Short Rake arms into tank and loosely bolt them at other 2 opposite sides of
torque cage.
Note:
Use temporary structure for supporting rake arms to prevent any damage to torque cage/rake arms till
the installation is correct.
11. Other Long Rake arm segments shall be lifted into tank and bolted to inner most and to
each other as per Delkor drawings. (Assembling in pairs of opposite segments will avoid
forcing of cage)

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
12. Similarly the Short Rake arm segments shall be lifted into tank and loosely bolted to inner
most and to each other as per Delkor drawings.
13. Check the alignment of rake arms with respect to torque cage and adjust if necessary. Now
tighten all bolts.
14. Also connect all Rake arms to torque cage using inclined tie rods. ( if applicable)
15. Now tie up all 4 rake arms together using horizontal tie rods.
16. Assemble Plastic slide to cage and Check for gap between plastic slide and center pier. Gap
should be uniform and no fouling allowed.
17. Now remove all temporary structures used for rake arms supporting.
18. Check for gap between Rake blades and tank floor. This should be uniform and per drawing.
They should not be touching the floor. Adjust the gap using inclined tie rods.
19. Rake arms shall be manually rotated and gap to be checked at various places. This should be
uniform and per drawing.
They should not be touching the floor. Adjust the gap using inclined tie rods.
Note: If lining is to be done for tank floor, the gap should be checked considering lining thickness.
20. Fit Underflow discharge cone scraper to torque cage & check for gap between scraper and
trench.
Note: No fouling allowed. Gap should be per delkor recommendation.
21. Lift feedwell segments into tank and keep them around torque cage and bolt up segments.
22. Fit V-notch plates of Auto dilution system onto feedwell.
23. Lift feedwell assembly up to bridge extension truss bottom and bolt it. Orientation need to
be taken care here before bolting.
24. Check for gap between bottom of feedwell and top of rake arms. [including lift - say
600mm)]. Fouling should not occur as feedwell is stationary and rakes are rotating
components)
25. Fix Feed drop box to bridge and pipe end to feedwell.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
26. Now lift feed pipe below the bridge and fit inner end to drop box/feedwell and outer end
on tank wall (If Feed pipe is under slung below bridge)
Note: Feed pipe slope shall be maintained as per GA drawings and upper end shall be on near tank periphery.
27. Now fit flocculent piping around the feedwell. Vertical pipes are to be bolted to truss.
28. Connect flocculent piping with header from dosing system.
29. Install Inline mixer on flocculent line (If ordered)
30. Lift Hydraulic powerpack near to drive on bridge.
31. Connect hydraulic powerpack to hydraulic motors and hydraulic cylinders using rigid piping
and flexible high pressure hoses.
32. Fill gearbox with recommended clean lubricant
33. Fill hydraulic powerpack with recommended clean lubricant.
34. Lift control panel near to powerpack and fit to bridge.
35. Install Mud level sensor (Interface level instrument) on bridge at approximately at half the
radius of tank.
36. Necessary electrical wiring shall be done for electric motors and to control panel.
37. Check direction of rotation of rakes after connecting power to hydraulic powerpack. Hoses
need to be interchanged between ports if rake is rotating is direction other than specified in
GA drawing.
38. While welding care must be taken so that surface finish is of high quality.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
POST-INSTALLATION INSTRUCTIONS:
1. Final painting will be required to be done as painting would have got peeled off because of
welding being at done at site. This is necessary to prevent exposure of unprotected surface.
2. For tanks with lining, it is recommended that lining shall be done after complete erection of
thickener. This is because temporary supports may be needed to erect bridge, drive and
rake mechanisms. These supports may damage lining if done prior to completion of
thickener erection.
3. Pre-commissioning Check list must be filled by Delkor representative in the presence of

client. (All previous checks will get automatically void).
4. All tools and any machinery used for installation shall be removed and surface shall be
cleaned thoroughly before feeding trial test water.
PRE-COMMISSIONING CHECK LIST
Sl. Check Reference Client / Delkor /

No. Represen Representative
tative
1 Tank bottom slope
Checked at min. 4 places at 90 to each GA
other
Cut off diameters where slope changes GA
2 Bridge
Mounting surface Elevation/Location GA/Foundation
details
Splice joints secured?
Hold down bolt size, Projection & GA/Foundation
Properly secured? details
Gratings & Handrails are properly
secured?
Feed pipe & Flocculent piping are
properly secured?
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
3 Bridge extension
Connection with Bridge and Tri-column
are properly secured?
Gratings & Handrails are properly
secured?
4 Feedwell
Segment joints are secured?
Aligned & properly secured to bridge
extension?
Deflector plate installed?
Auto dilution v-notch installed?
Bottom gap to rake arm exists in lifted
condition?
Orientation correct?
Drop box connected?
Feed pipe connected at correct elevation
and orientation?
5 Rake arms
Tank bottom gap-within limits?
Splice joints secured?
Arms are secured to torque cage?
Arms are aligned?
Arms are in correct position?
Blades in correct direction?
Tie rods fitted?
6 Torque cage
Secured to Ring Gear interface?
Gap between center pier and torque
cage-within limits?
Plumb checked?
7 Trench Scrapers
Trench scrapers secured?
Gap with trench?
8 Center pier
Properly secured to foundation?
Elevations are correct? GA
9 Drive
Center pier Interface secured?
Tri-column secured?
Over travel safety sensors installed?
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Check for any grits on sliding surfaces?
No Fouling with stationary components
ensured?
Hoses are secured properly?
Hydraulic pipe fittings secured?
Ring Gear and Pinion are grease
lubricated?
Correct grade & Qty of Gearbox Oil
filled?
Rotary motion checked?
Vertical movement checked?
10 Hydraulic Powerpack
Correct grade & Qty of Powerpack Oil
filled?
Oil Filter installed & clean?
Pressure settings done?
Low level oil switch installed?
11 Overflow weir V-notch plate
installed?
12 Final painting done?
13 Name plate installed?
14 Safety signs installed?
15 All Fasteners are of recommended GA
grades
16 All shipping ties removed?
17 All temporary structures removed?

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Illustration showing equal gap between tank floor and rake blades
Illustration showing adjustment of deflector plate gap

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Illustration showing hydraulic motor fixing to gearbox

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Placement of drive frame into Tri-column vertically down
(Orientation and surface damage control is to be taken care while
Lowering drive frame)

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Bridge extension being assembled
Bridge extension assembled

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Connecting bridge segment to bridge extension trusses
Aligning Bridge and bridge extension trusses

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Feedwell segments being hung from bridge extension
Feedwell segments being assembled

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Feedwell gap setting
Rake arms assembling

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Rake arms blades assembled
Rake arms after assembly

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Plastic Slides between torque cage and center pier for tilt control
(Observe clearances by rotating torque cage)
Underflow Trench scraper assembly (Observe clearances with trench)

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Feed pipe segments being connected
Feed pipe assembled

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Flocculent feed pipe assembly. After installation

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Drive assembly after installation

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Hose connections from Powerpack to hydraulic motors & Cylinders

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Automatic Grease lubrication unit for drive

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Automatic Grease lubrication unit for drive

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
Level sensor mounting for Lift Control

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
LOCAL CONTROL PANEL

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01
After Installation, but before commissioning,
Your thickener should look like or similar to this.
Installation completed and tank being feed with water for trial run.

+56 (2) 650 47 24
+56 (2) 650 47 00 (Central)
+56 (2) 650 47 01

THICKENER Mechanism - Center Pier Type Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

THICKENER Mechanism - Center Pier Type Manual

Uploaded by

Copyright:

Available Formats

FOR

DELKOR (SOUTH AMERICA) LTDA.

2. Mechanism components would have been supplied in multiple parts depending on

3. Components parts need to be welded or bolted depending on design considered.

4. Necessary erection equipment/tools shall be provided by client.

6. All safety precautions should be taken care while welding at site.

7. Drive is supplied as a completely assembled single unit except for powerpack.

8. Gearboxes and hydraulic powerpack are supplied without filling lubricant.

10. Mechanism generally consists of the following items.

DELKOR (SOUTH AMERICA) LTDA.

11. General checks :

DELKOR (SOUTH AMERICA) LTDA.

(FOR CLIENT SUPPLIED METALLIC TANKS/CONCRETE TANKS)

2. Circularity of tank for eccentricity. Eccentricity should be within allowable limits.

3. Tank assembly is complete and anchored properly with relevant bolts.

7. Tank dimensions per Delkor drawing.

8. Center pier dimensions per delkor drawing. (If applicable)

9. Launder dimensions and orientation of overflow pipe per Layout drawing.

10. V-notch plates are fixed.

11. Underflow cone or trench per drawing and orientation of pipes.

PRE CHECKS REQUIRED:

1. Ensure all parts required are received before accepting shipment

DELKOR (SOUTH AMERICA) LTDA.

5. Installation Instruction sheets/Manual must be at the erection place.

6. Ensure the inaccessible surfaces of components are painted before installation.

DELKOR (SOUTH AMERICA) LTDA.

2. Assemble bridge segments on floor.

7. Install Toe-guards alongside of handrails.

8. Bolt up rake blades to Rake arms on floor.

DELKOR (SOUTH AMERICA) LTDA.

22. Fit V-notch plates of Auto dilution system onto feedwell.

DELKOR (SOUTH AMERICA) LTDA.

28. Connect flocculent piping with header from dosing system.

29. Install Inline mixer on flocculent line (If ordered)

30. Lift Hydraulic powerpack near to drive on bridge.

32. Fill gearbox with recommended clean lubricant

33. Fill hydraulic powerpack with recommended clean lubricant.

34. Lift control panel near to powerpack and fit to bridge.

DELKOR (SOUTH AMERICA) LTDA.

3. Pre-commissioning Check list must be filled by Delkor representative in the presence of

PRE-COMMISSIONING CHECK LIST

Sl. Check Reference Client / Delkor /

DELKOR (SOUTH AMERICA) LTDA.

Illustration showing adjustment of deflector plate gap

DELKOR (SOUTH AMERICA) LTDA.

DELKOR (SOUTH AMERICA) LTDA.

DELKOR (SOUTH AMERICA) LTDA.

Bridge extension assembled

DELKOR (SOUTH AMERICA) LTDA.

Aligning Bridge and bridge extension trusses

DELKOR (SOUTH AMERICA) LTDA.

Feedwell segments being assembled

DELKOR (SOUTH AMERICA) LTDA.

Rake arms assembling

DELKOR (SOUTH AMERICA) LTDA.

Rake arms after assembly

DELKOR (SOUTH AMERICA) LTDA.

Underflow Trench scraper assembly (Observe clearances with trench)

DELKOR (SOUTH AMERICA) LTDA.

Feed pipe assembled

DELKOR (SOUTH AMERICA) LTDA.

DELKOR (SOUTH AMERICA) LTDA.

DELKOR (SOUTH AMERICA) LTDA.