WQ0005555_Add Info Response-Major Mod Application_20190403

►� =Com Delivered.
d.
►� Delivered.
Date: March 18, 2019
TO: Tessa Monday
NCDEQ-Division of Water
Resources
512 N. Salisbury St.
Raleigh, NC 27604
RE: APPLICATION NO. WQ0005555
The following items are being sent:
❑ Shop Drawings ❑ Prints
❑ Other O&M Info
LETTER OF TRANSMITTAL
FROM: Krista Paredes -Toledo, PE
URS Corporation — North
Carolina
1600 Perimeter Park Drive
Suite 400
Morrisville, NC 27560
AECOM #: 60599459
❑Attached ❑ Under separate cover by
❑ Plans ❑ Samples ❑ Specifications ❑ Copy of Letter
Item
Copies
Date
Description
1
1
March 18, 2019
Weyerhaeuser Cover Letter
2
1
March 18, 2019
Form WWIS 06-16
3
2
March 18, 2019
Plans (half-size)
4
2
March 18, 2019
O&M Info
5
1
March 18, 2019
CD with above documents
Transmittals for reasons checked:
❑ For Your Approval ❑ No Exceptions Taken ❑ Resubmit copies for approval
❑ For Your Use ❑ Make Corrections Noted ❑ Submit copies for distribution
❑ As Requested ❑ Amend and Resubmit ❑ Return all 4 copies of signed documents
❑ For Review and Comment ❑ Execute 6 copies for distribution
Remarks: Check for fee of $395 to be submitted ASAP by AECOM
Copies: Dennis Atkinson w/enclosure except CD, File w/o encl.
If enclosures are not as noted, kindly notify us at once.
AECOM Technical Services of NC
1600 Perimeter Park Drive, Suite 400
Morrisville, NC 27560
919-461-1100
Krista Paredes -Toledo, PE
Letter of Transmittal
3/ t A/20 t 9

Weyerhaeuser
March 15, 2019
NC DENR
Division of Water Quality
Aquifer -Protection Section, Land Application unit
1636 Mail Service Center
Raleigh, North Carolina, 27699-1636
RE: Non -Discharge System Renewal Application
Permit No. WQ0005555
Weyerhaeuser NR Company--- Surry County
To Whom It May Concern,
Please find enclosed our major modification permit renewal application for continued use of our existing spray
fields. In preparation for connecting to our local publicly owned treatment work (POTW) plant operated by the
Yadkin Valley Sewer Authority (YVSA) for Industrial Wastewater as well as Sanitary waters, we have replaced
several components of our treatment system to meet YVSA's Industrial User Permit standards. Namely we have
replaced the "stand-by vacuum filter system for solids dewatering' with a Dissolved Air Floatation and Belt
Press Systems. Additionally, the "230,000-gallon anoxic reactor lagoon with a synthetic tarp cover; a 190,000
gallon aerated pond" have been converted to a series of settling ponds. Below is the description paragraph to
replace the one that is currently in the permit.
"three side hill screens; a pre-calibratcd McCrometer UltraMag influent flow meter; a pH control system to buffer
pH up or down; a defoaming system; a 4,800-gallon surge tank; a polymer addition system for solids
removal; a static mixer; a 93,508-gallon flocculating clarifier; a 1,400-gallon sludge storage tank; Dissolved Air
Flotation and a Belt Press system for solids dewatering; a 420,000 gallon settling pond connected in series with
a 840,000-gallon settling pond and a 420,000-gallon irrigation pond with aeration available if needed; a 250-
gallon per minute vertical chopper pump; and existing 16.13 acre solid set irrigation system and an additional
8.53 acres of spray irrigation area with fixed spray heads with 9/32- inch Senninger nozzles installed in 2013 for
a total irrigation area of 24.66 acres and (ultimate disposal capacity of 44,175 GPD) and all associated piping,
valves, and other appurtenances;"
After connection to YVSA, we will be reducing the usage of our spray fields with the plans of closing out some
of the older spray zones. We do not want to eliminate all of our spray fields. We would like to keep the newer
spray fields as a back-up discharge system for when YVSA cannot take our waste water.
Enclosed with this letter is the following:
• Signed Form WWIS 06-16
• Record Drawings for the DAF and Belt Press units
• Operations and Maintenance Data for DAF and Belt Press units
If you have any questions please contact Dennis Atkinson at [phone] or via e-mail
([e-mail]).
Sin rely,
Dennis Atkinson
Environmental Manager
Weyerhaeuser NR Company

State of North Carolina
Department of Environmental Quality
DWR Division of Water Resources
15A NCAC 02T .0500 — WASTEWATER IRRIGATION SYSTEMS
Division of Water Resources FORM: WWIS 06-16
I. APPLICANT INFORMATION:
1. Applicant's name: Weyerhaeuser
2. Applicant type: ❑ Individual ® Corporation ❑ General Partnership ❑ Privately -Owned Public Utility
❑ Federal ❑ State ❑ Municipal ❑ County
3. Signature authority's name: Dennis Atkinson per 15A NCAC 02T .0106(b) Title: Environmental Manager
4. Applicant's mailing address: 524 Pride Way
City: Elkin State: NC Zip: 28621-
5. Applicant's contact information:
Phone number: [phone] Email Address: dennis.atkinson(a)weyerhaeuser.com
II. FACILITY INFORMATION:
1. Facility name: Elkin OSB ManufacturingFcility
2. Facility status: Existing
3. Facility type: Major (> 10,000 GPD or > 300 disposal acres)
4. Facility's physical address: 524 Pride Way
City: Elkin State: NC Zip: 28621- County: Sunj
5. Wastewater Treatment Facility Coordinates (Decimal Degrees): Latitude: 36.254502' Longitude:-80.786642'
Datum: Unknown Level of accuracy: Unknown Method of measurement: Address matching
6. USGS Map Name: Yadkinville, NC
III. CONSULTANT INFORMATION:
1. Professional Engineer: Krista Paredes -Toledo License Number: 044627 Firm: AECOM
Mailing address: 1600 Perimeter Park Drive, Suite 400
City: Morrisville State: NC Zip: 27560-
Phone number: [phone] Email Address: krista.paredesnaecom.com
2. S��ientist: N/A License Number: Firm: /
Mailing a
City: Zip: -
Phone number: O - Email Address: _
3. Geologist: N/A nse Number:
Mailing address:
City: State: Zip: -
Phone number: (_) _- E ddress:
4. Agronomist: N/A Firm:
Mailing address:
City: State: Zip: -
Ph o umber: () - Email Address:
FORM: WWTS 06-16 Page 1 of 12

IV. GENERAL REQUIREMENTS —15A NCAC 02T .0100:
1. Application type: ❑ New ® Major Modification ❑ Minor Modification
If a modification, provide the existing permit number: WQ0005555 and most recent issuance date: May 1, 2014
2. Application fee: $395 - Standard - Major Facility - Major Mod
3. Does this project utilize public monies or lands? ❑ Yes or ® No
If yes, was an Environmental Assessment required under 15A NCAC 01 C? ❑ Yes or ❑ No
If yes, which final environmental document is submitted? ❑ Finding of No Significant Impact or ❑ Record of Decision
Briefly describe any mitigating factors from the Environmental Assessment that may impact this facility:
4. What is the status of the following permits/certifications applicable to the subject facility?
Permit/Certification
Date
Submitted
Date
Approved
Permit/Certification
Number
Agency Reviewer
Collection System (Q > 200,000 GPD)
Dam Safety
Erosion & Sedimentation Control Plan
Nationwide 12 / Section 404
Pretreatment
Sewer System
Stormwater Management Plan
8/1/18
NCG210115
N/A
Wetlands 401
Other: Cooling Tower Permit
11/25/15
NCG500272
N/A
5. What is the wastewater type? ❑ Domestic or Industrial (See 15A NCAC 02T .0103(20))
Is there a Pretreatment Program in effect? ® Yes or ❑ No
Has a wastewater chemical analysis been submitted? ® Yes or ❑ No
6. Wastewater flow: 28,8000 GPD
Limited by: ® Treatment, ❑ Storage, ❑ Field Hydraulics, ❑ Field Agronomics or ❑ Groundwater Mounding
7. Explain how the wastewater flow was determined: ❑ 15A NCAC 02T .0114 or ® Representative Data
Has a flow reduction been approved under 15A NCAC 02T .0114(f)? ❑ Yes or ® No
Establishment Type
Daily Design Flow a
No. of Units
Flow
gal/
GPD
gal/
GPD
gal/
GPD
gal/
GPD
gal/
GPD
gal/
GPD
Total
GPD
a See 15A NCAC 02T .0114(b), (d), (e (1) and (e)(2), for caveats to wastewater design flow rates (i.e., minimum flow per
dwelling; proposed unknown non-residential development uses; public access facilities located near high public use
areas; and residential property located south or east of the Atlantic Intracoastal Waterway to be used as vacation rentals
as defined in G.S. 42A-4).
FORM: WWiS 06-16 Page 2 of 12

IV. GENERAL REQUIREMENTS —15A NCAC 02T .0100 (continued):
8. What is the nearest 100-year flood elevation to the facility? 884 feet mean sea level. Source: FEMA FIRM Map
3710497100K
Are any treatment, storage or irrigation facilities located within the 100-year flood plain? ❑ Yes or ® No
If yes, which facilities are affected and what measures are being taken to protect them against flooding`?
If yes, has the Applicant submitted written documentation of compliance with § 143 Article 21 Part 6? ❑ Yes or ❑ No
9. Has the Applicant provided documentation of the presence or absence of threatened or endangered aquatic species utilizing
information provided by the Department's Natural Heritage Prog am? ❑ Yes or ® No
10. Does the facility have a proposed or existing groundwater monitoring well network? ® Yes or ❑ No
If no, provide an explanation as to why a groundwater monitoring well network is not proposed:
If yes, complete the following table (NOTE — This table may be expanded for additional wells):
Well Name
Status
Latitude a
Longitude a
Gradient
Location
W-4
Active
36.252036'
-80.790436'
Select
Inside Review Boundary
W-5
Active
36.255681 °
-80.793397'
Select
Inside Review Boundary
W-6
Select
36.258281 °
-80.789036'
Select
Outside Compliance Bou
W-7
Select
36.258042"
-80.788275'
Select
Outside Compliance Bou
W-8
Select
36.257817"
-80.787875'
Select
Outside Compliance Bou
W-9
Select
36.2568780
-80.78751 V
Select
Outside Compliance Bou
W-10
Select
36.2534560
-80.7918530
Select
Inside Field
W-11
Select
36.2552310
-80.7960170
Select
Inside Compliance Bounc
W-12
Select
36.2506110
-80.7942220
Select
Inside Review Boundary
Select
-
Select
Select
a Provide the following latitude and longitude coordinate determination information:
Datum: NAD83 Level of accuracy: Nearest 10th of a second Method of measurement:
Conversion from state coordinate plane
11. If the Applicant is a Privately -Owned Public Utility, has a Certificate of Public Convenience and Necessity been submitted?
❑ Yes, ®No or ❑N/A
12. If the Applicant is a Developer of lots to be sold, has a Developer's Operational Agreement (FORM: DEV) been submitted?
❑ Yes, ®No or ❑N/A
13. If the Applicant is a Home/Property Owners' Association, has an Association Operational Agreement (FORM: HOA) been
submitted? ❑ Yes, ®No or ❑N/A
14. Demonstration of historical consideration for permit approval — 15A NCAC 02T .0120:
Has the Applicant or any parent, subsidiary or other affiliate exhibited the following?
a. Has been convicted of environmental crimes under Federal law or G.S. 143-215.613? ❑ Yes or ® No
b. Has previously abandoned a wastewater treatment facility without properly closing that facility? ❑ Yes or ® No
c. Has unpaid civil penalty where all appeals have been abandoned or exhausted? ❑ Yes or ® No
d. Is non -compliant with an existing non -discharge permit, settlement agreement or order? ❑ Yes or ® No
e. Has unpaid annual fees in accordance with 15A NCAC 02T .0105(e)(2)? ❑ Yes or ® No
FORM: WWiS 06-16 Page 3 of 12

V. WASTEWATER TREATMENT FACILITY DESIGN CRITERIA —15A NCAC 02T .0505:
1. For the following parameters, provide the estimated influent concentrations and designed effluent concentrations as
termined in the Engineering Calculations, and utilized in the Agronomic Evaluation and Groundwater Modelin if
ap 'cable):
Para ter
Estimated Influent Concentration
Designed Effluent oncentration
monthl vera e
Ammonia 'trogen (NH3-N)
mg/L
mg/L
Biochemical gen Demand (BODS)
mg/L
mg/L
Fecal Coliforms
per 100 mL
Nitrate Nitrogen (NO3-
mg/L
mg/L
Nitrite Nitrogen (NO2-N)
mg/L
mg/L
Total Kjeldahl Nitrogen
mg/L
Total Nitrogen
mg/L
mg/L
Total Phosphorus
mg/L
mg/L
Total Suspended Solids (TSS)
mg/L
mg/L
2. Is flow equalization of at least 25% of the avera daily flow prov' ed? ❑ Yes or ❑ No
3. Does the treatment facility include any bypass or ov ow lin . ❑ Yes or ❑ No
If yes, describe what treatment units are bypassed, why i s necessary, and where the bypass discharges:
4. Are multiple pumps provided wherever pumps are use es or ❑ No
If no, how does the Applicant intend on complying ith 15A C 02T .0505 k ?
5. Check the appropriate box describing how pow reliability will be ovided in accordance with 15A NCAC 02T .0505(1):
❑ Automatically activated standby power pply onsite capable of p ering all essential treatment units; or
❑ Approval from the Director that the cility:
➢ Has a private water supply t automatically shuts off during power 'lures and does not contain elevated water
storage tanks;
➢ Has sufficient storage acity that no potential for overflow exists; and
➢ Can tolerate septic tewater due to prolonged detention.
6. If the wastewater treatme system is located within the 100-year flood plain, are there w r-tight seals on all treatment units
or a minimum of two f protection from the 100-year flood plain elevation? ❑ Yes, ❑ or ® N/A
7. In accordance with A NCAC 02T .0505 0 , how many days of residuals storage are provide .
8. How does the licant propose to prohibit public access to the wastewater treatment and storage ilities? Private lot with
securit ates
9. If an infl t pump station is part of the proposed facility (i.e., within the wastewater treatment plant bou ary), does the
influen ump station meet the design criteria in 15A NCAC 02T .0305(h)? ❑ Yes, ❑ No, ❑ N/A — To b ermitted
sepa ely, or ❑ N/A — Gravity fed
10. I ptic tanks are part of the wastewater treatment facility, do the septic tanks adhere to the standards in 15A NC 18A
900? ❑ Yes, ❑ No or ❑ N/A
FORM: WWiS 06-16 Page 4 of 12

V. WASTEWATER TREATMENT FACILITY DESIGN CRITERIA —15A NCAC 02T .0505 (continued):
I I . Provide the requested treatment unit and mechanical equipment information:
a. PRELIMINARY / PRIMARY TREATMENT (i.e., physical removal operations and flow equalization):
No. of
Manufacturer or
Dimensions (ft) /
Volume
Plan Sheet
Specification
Treatment Unit
Units
Material
Spacings (in)
(gallons)
Reference
Reference
Dissolved Air Floatatio
1
Palmetto Water
13'Wx40'L
600gpm
07
N/A
Solutions
Select
Select
Select
Select
SECONDARY / TERTIARY TREATMENT (i.e., biological and chemical processes to remove organics and nutrie0*00000
Tre:at�medNo.
Treatmen t
of
Units
Manufacturer or
Material(gallons)
Dimensions (ft)
Volume
Plan Shee
R ce
ecification
Reference
Select
Select
Select
Select
Select
Select
Select
e ect
001"-
c. DISINFECTION
No. of
Manufacturer or
Volume
Plan S
ecification
Treatmen
Dimensions (ft)
w,LLnits
Material
(gallons)
rence
I Reference
Select
Select
➢ If chlorination is the proposed method of ion, specify deten rovided: minutes (NOTE — 30
minutes minimum required), an e what treatment unit chlorine contact o
➢ If ultraviolet ( is the proposed method of disinfection, specify the number of banks: ber of lamps
per ba and maximum disinfection capacity: GPM.
RESIDUAL TREATMENT
No. of
Manufacturer or
Volume
Plan Sheet
Specification
Treatment Unit
Dimensions (ft)
Units
Material
(gallons)
Reference
Reference
Thickening - Belt Press
1
Ashbrook
11.25'Wxl8'Lx10'H
125 gpm
05/06
N/A
Select
FORM: WWiS 06-16 Page 5 of 12

V. ASTEWATER TREATMENT FACILITY DESIGN CRITERIA —15A NCAC 02T .0505 (continued):
e. PUMPS
Location
No. of
Pumps
purpose
Manufacturer /
Type
Capacity
Plan Sheet
Reference
Specif ation
Re rence
GPM
TDH
f. BLOWERS
Location
No. of
No.
nits Served
Manufacturer /
Type
Capacity
(CFM
Plan Sheet
Reference
Specification
Reference
g. MIXERS
Location
No. of
Mixers
Units Served
anufacturer /
Type
Power
h
Plan Sheet
Reference
Specification
Reference
h. RECORDING DEVICES & RELIA/LITY \
Device
No. of
Units
Location
Manufacturer
aximum
Vapacity
Plan Sheet
Reference
Specification
Reference
Select
OF
Select
Select
Select
i. EFFLUENTAP / FIELD DOSING TANK (IF APPLICABLE): \
Plan eet
Refere a
Specification
Reference
Internal mensions (L x W x H or (p x H)
ft
ft
ft
Tota olume
ft3
gallons
D ing volume
ft3
gallons
Audible & visual alarms
Equipment to prevent irrigation during rain events
WWIS 06-16
Page 6 of 12

VI. NEARTHEN IMPOUNDMENT DESIGN CRITERIA —15A NCAC 02T .0505:
1. at is the earthen impoundment type? Select
2. Stor e Impoundment Coordinates (Decimal Degrees): Latitude: 0Longitude: - °
Datum: lect Level of accuracy: Select Method of measurement: Select
3. Do any imp ndments include a discharge point (pipe, spillway, etc)? ❑ Yes or ❑ No
4. Are subsurface ains present beneath or around the impoundment to control groundwater elevation? es or ❑ No
5. Is the impoundme designed to receive surface runoff? ❑ Yes or ❑ No
If yes, what is the drat ge area? ft2, and was this runoff incorporated into the water Bala c'? ❑ Yes or ❑ No
6. If a liner is present, how ' 1 it be protected from wind driven wave action?:
7. Will the earthen impoundme water be placed directly into or in contact with GA classif groundwater? ❑ Yes or ❑ No
If yes, has the Applicant provide redictive calculations or modeling demonstrating t t such placement will not result in a
contravention of GA groundwater ndards? ❑ Yes or ❑ No
8. What is the depth to bedrock from the rthen impoundment bottom elevation? ft
If the depth to bedrock is less than four fe has the Applicant provided a lin with a hydraulic conductivity no greater than
1 x 10-7 cm/s? ❑ Yes, �o or ❑ N/A
Has the Applican rovided predictive ca lations or modeling demonstrating that surface
water or groundwat standards will no e contravened? ❑ Yes or ❑ No
If the earthen impoundment is excavated into bedroc , as the Ap cant provided predictive calculations or modeling
demonstrating that surface water or groundwater standa will t be contravened? ❑ Yes, ❑ No or ❑ N/A
9. If the earthen impoundment is lined and the mean seasonal ' water table is higher than the impoundment bottom
elevation, how will the liner be protected (e.g., bubbling, water infiltration, etc.)?
10. If applicable, provide the specification page references r the lin installation and testing requirements:
11. If the earthen impoundment is located within the 10 year flood plai as a minimum of two feet of protection (i.e., top of
embankment elevation to 100-year flood plain el tion) been provide Yes or ❑ No
12. Provide the requested earthen impoundment d ign elements and dimensio :
Earthen Impoundment Desig Aements
= Ea en Impoundment Dimensions
Liner type:
❑ Cl
❑ Synthetic
Top of embankmen levation:
ft
❑ her
❑ Unlined
Liner hydraulic conductivity:
x - cm/s
Freeboard elevation:
ft
Hazard class:
Select
Toe of slope elevation:
ft
Designed freeboard:
ft
Impoundment bottom elevatio
ft
Total volume:
ft3
gallons
Mean seasonal high water table de
ft
Effective volume:
ft3
gallons
Embankment slope:
Effective stora time:
days
Top of dam water surface area:
ft2
Plan Sheet eference:
Freeboard elevation water surface area:
ft2
Specifi ion Section:
Bottom of impoundment surface area:
ft2
/eTboard
The effective volume shall be the volume between the two foot freeboard elevation and the: (1) pump intake ' e
n; (2) impoundment bottom elevation or (3) mean seasonal high water table, whichever is closest to the two foot
elevation.
FORM: WWTS 06-16 Page 7 of 12

VII.
IRRIGATION SYSTEM DESIGN CRITERIA —15A NCAC 02T .0505:
\Evalua
he minimum depth to the seasonal high water table within the irrigation area:
The vertical separation between the seasonal high water table and the ground surface shall be at least one fo
any artificial drainage or water movement structures (e.g., surface water or groundwater) within 200 fe f the
area? ❑ Yes or ❑ No
r ese structures addressed in the Soil Evaluation and/or Hydrogeologic Report, and are these s ctures to be
ed o odified?
uation r mmended loading rates (NOTE — This table may be expanded for additional soil ries):
Soil Series
Fields within
oil Series
Recommended
Loading Rate
in/hr
Recommended
Loading Rate
in/ r
Annual /Sea al
Loadi
If Seasonal, list
appropriate
months
ect
Select
Select
Select
Select
Select
4. Are the designed loading rates less than or equal to X
If no, how does the Applicant intend on complying
5. How does the Applicant propose to prohibit public 6. Has the irrigation system been equipped with a flow
field as listed in VII.8.? ❑ Yes or ❑ No
If no, how does the Applicant intend on comp ng with 15A NC
recommended loading rates? ❑ Yes or ❑ No
C 02T .0505(n)?
n system?
determine the volume of effluent applied to each
7. Provide the required cover crop informati and demonstrate the effluent wi be applied at or below agronomic rates:
Cover Crop
Soil ies
% Slope
Nitrogen take Rate
lbs/a r
Phosphorus Uptake
Rate lbs/ac r
/inimum
e the nitrogen and phosphorus uptake rates for each cover crop were obtained:
itrogen mineralization rate:
itrogen volatilization rate:
rrigation area from the Agronomist Evaluation's nitrogen balance: ft2
rrigation area from the Agronomist Evaluation's phosphorus balance: ft2
rrigation area from the water balance: ft2
FORM: WWTS 06-16 Page 8 of 12

VII. IRRIGATION SYSTEM DESIGN CRITERIA —15A NCAC 02T .0505 (continued):
Field Information (NOTE — This table may be expanded for additional fields):
Id
Area
(acres)
Dominant
Soil Series
Designed
Loading
Rate
(in/hr)
Designed
Loading
Rate
(in/ r)
Latitude'
Longitude a
Wat
n
Streamm Indydex
NO, a
;/ication
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o
0
0
o
0
o
0
00,1 O
0
0
0
0
0
0
O
0
0
0
0
0
0
Total
a Provide the following latitude
Datum: Select Level of
b For assistance determine50
downloaded at: http://dA.j
longitude coordinate determination
Select Method of measurement: Select
waterbody stream index number and its associated cla'%ification, instructions may be
Spray Irr' ation Design Elements
Drip Irrigation ign Elements
Nozzle wetted dia ter:
ft
Emitter wetted area:
ft2
Nozzle wetted ea:
ft2
Distance between laterals:
ft
Nozzle cap ity:
GPM
Distance between emitters:
ft
Nozzle nufacturer/model:
/
Emitter capacity:
GPH
Elev on of highest nozzle:
ft
Emitter manufacturer/model:
/
S cification Section:
Elevation of highest emitter:
ft
or
Specification Section:
RM:
WWiS 06-16
Page 9 of 12

VIII. SETBACKS —15A NCAC 02T .0506:
1. Does the project comply with all setbacks found in the river basin rules (15A NCAC 02B .0200)? ® Yes or ❑ No
If no, list non -compliant setbacks:
2. Have any setback waivers been obtained in order to comply with 15A NCAC 02T .506(a) and .0506 b ? ❑ Yes or ® No
If yes, have these waivers been written, notarized and signed by all parties involved and recorded with the County Register of
Deeds? ❑ Yes or ❑ No
3. Provide the minimum field observed distances (ft) for each setback parameter to the irrigation system and treatment/storage
units (NOTE — Distances greater than 500 feet may be marked N/A):
Setback Parameter
Irrigation
System
Treatment /
�Storage Units
Any habitable residence or place of assembly under separate ownership or not to be
maintained as part of the pro'ect site
400
N/A
Any habitable residence or place of assembly owned by the Permittee to be maintained as
art of the project site
N/A
Any private or public water supply source
N/A
N/A
Surface waters (streams — intermittent and perennial, perennial waterbodies, and wetlands)
120
N/A
Groundwater lowering ditches (where the bottom of the ditch intersects the SHWT)
N/A
Subsurface groundwater lowering drainage systems
N/A
Surface water diversions (ephemeral streams, waterways, ditches)
100
Any well with exception of monitoring wells
100
100
Any property line
150
150
Top of slope of embankments or cuts of two feet or more in vertical height
N/A
Any water line from a disposal system
N/A
Any swimming pool
N/A
Public right of way
N/A
Nitrification field
N/A
Any building foundation or basement
400
Impounded public water supplies
N/A
Public shallow groundwater supply (less than 50 feet deep)
N/A
4. Does the Applicant intend on complying with 15A NCAC 02T .0506(c) in order to have reduced irrigation setbacks to
property lines? ❑ Yes or ® No
If yes, complete the following table by providing the required concentrations as determined in the Engineering Calculations:
Estimated Influent
Designed Effluent
Designed Effluent
Parameter
Concentration
Concentration
Concentration
(monthly average)
(daily maximum
Ammonia Nitrogen (NH3-N)
mg/L
mg/L
mg/L
Biochemical Oxygen Demand (BODS)
mg/L
mg/L
mg/L
Fecal Coliforms
per 100 mL
per 100 mL
Total Suspended Solids (TSS)
mg/L
mg/L
mg/L
Turbidity
NTU
FORM: WWiS 06-16 Page 10 of 12

IX. COASTAL WASTE TREATMENT DISPOSAL REQUIREMENTS —15A NCAC 02H .0400:
1. Is this facility located in a Coastal Area as defined per 15A NCAC 02H .0403? ❑ Yes or ® No
For assistance determining if the facility is located within the Coastal Area, a reference map may be downloaded at: Coastal
Areas Boundary.
2. Is this an Interim Treatment and Disposal Facility per 15A NCAC 02H .0404(Q)? ❑ Yes or ® No
NOTE — Interim facilities do not include County and Municipal area -wide collection and treatment systems.
ANSWERED YES TO ITEMS IX.1. AND IX.2., THEN COMPLETE ITEMS IX.3. THROUGH IX.17.
3. ualization of at least 25% of the average daily flow provided? ❑ Yes or ❑ No
4. How oise and odor be controlled?
5. Is an automat activated standby power source provided? ❑ Yes or ❑ No
6. Are all essential tre�NCAC
s provided in duplicate? ❑ Yes or ❑ No
NOTE — Per 15A .0103 16 , essential treatment units are defined as unit associated with the wastewater
treatment process whose loss uld likely render the facility incapable of eting the required performance criteria,
including aeration units or other m ' treatment units, clarification equi t, filters, disinfection equipment, pumps and
blowers.
7. Are the disposal units (i.e., irrigation fields) pro ii d in duplica g., more than one field)? ❑ Yes or ❑ No
8. Is there an impounded public surface water supply wit ' feet of the wetted area? ❑ Yes or ❑ No
9. Is there a public shallow groundwater supply (less n 50 fe eep) within 500 feet of the wetted area? ❑ Yes or ❑ No
10. Is there a private groundwater supply withi 0 feet of the wetted a ? ❑ Yes or ❑ No
11. Are there any SA classified waters ' in 100 feet of the wetted area? ❑ or ❑ No
12. Are there any non -SA classif waters within 50 feet of the wetted area? ❑ Yes No
13. Are there any surface er diversions (i.e., drainage ditches) within 25 feet of the wette ea? ❑ Yes or ❑ No
14. Per the require is in 15A NCAC 02H .0404(g)(7), how much green area is provided?
15. Is the gr area clearly delineated on the plans? ❑ Yes or ❑ No
16. I e spray irrigation wetted area within 200 feet of any adjoining properties? ❑ Yes, ❑ No or ❑ N/A (i.e., ip irrigation)
. Does the designed annual loading rate exceed 91 inches? ❑ Yes or ❑ No
FORM: WWTS 06-16 Page 11 of 12

Professional Engineer's Certification:
attest that this application for
(Professional Engineer's name from Application Item 111.1.)
(Facility name from Application Item II.I.)
has been reviewed by me and is accurate, complete and consistent with the information supplied in the plans, specifications,
engineering calculations, and all other supporting documentation to the best of my knowledge. I further attest that to the best of my
knowledge the proposed design has been prepared in accordance with this application package and its instructions, as well as all
applicable regulations and statutes. Although other professionals may have developed certain portions of this submittal package,
inclusion of these materials under my signature and seal signifies that I have reviewed this material and have judged it to be consistent
with the proposed design.
NOTE — In accordance with General Statutes 143-215.6A and 143-215.6S, any person who knowingly makes any false statement,
representation, or certification in any application package shall be guilty of a Class 2 misdemeanor, which may include a fine not to
exceed $10,000, as well as civil penalties up to $25,000 per violation.
North Carolina Professional Engineer's seal, signature, and date:
Applicant's Ce ation per 15A NC6C 02T .0
110
- SEAL
044627 10
"141
1/lriV
attest that this application for
ignature Authority's
& title from Application Item
r. { 1. I
(Facility name from Application Ite� I1.1.)
has been reviewed by me and is accurate and complete to the best of my knowledge. I understand that any discharge of wastewater
from this non -discharge system to surface waters or the land will result in an immediate enforcement action that may include civil
penalties, injunctive relief, and/or criminal prosecution. I will make no claim against the Division of Water Resources should a
condition of this permit be violated. I also understand that if all required parts of this application package are not completed and that
if all required supporting information and attachments are not included, this application package will be returned to me as incomplete.
I further certify that the Applicant or any affiliate has not been convicted of an environmental crime, has not abandoned a wastewater
facility without proper closure, does not have an outstanding civil penalty where all appeals have been exhausted or abandoned, are
compliant with any active compliance schedule, and do not have any overdue annual fees per 15A NCAC 02T .0105(e).
NOTE .. In accordance with General Statutes 143-215.6A and 143-215.G13. any person who knowingly makes any false statement,
representation, or certification in any application package shall be guilty of a Class 2 misdemeanor, which may include a fine not to
exceed S I0, well as civil penalties p to $25 000 er violation.
Signature: t Date:
FORM: WWIS 06-16 Page 12 of 12

WEYERHAEUSER NR COMPANY
LOCATION MAP
SUMMARY OF WORK:
• NEW DISSOLVED AIR FLOTATION SYSTEM
• NEW 2 METER BELT PRESS
Weyerhaeuser
ELKIN, NORTH CAROLINA
RECORD DRAWINGS FOR
PERMIT WQ0005555
Vicinity Map
NOT TO SCALE
PROJECT CONTACTS
OWNER:
DENNIS ATKINSON
WEYERHAEUSER NR COMPANY
524 PRIDE WAY
ELKIN, NC 28621
(P) (336) 835 — 5100
[e-mail]
www.weyerhaeuser.com
INDEX OF SHEETS
ENGINEER:
KRISTA PAREDES—TOLEDO, PE
AECOM TECHNICAL SERVICES OF NC
1600 PERIMETER PARK DRIVE, SUITE 400
MORRISVILLE, NC 27560
(P) [phone]
[e-mail]
www.cecom.com
COVER SHEET
00
OVERALL SITE PLAN
01
PLANT AREA
SITE PLAN
02
SPRAY FIELD
AREA/SOILS
MAP
03
PROCESS FLOW DIAGRAM
04
BELT PRESS
GENERAL ARRANGEMENT
05
BELT PRESS
ROLLER CONFIGURATION
06
WASTEWATER
TREATMENT
PLAN GENERAL ARRANGEMENT
07
WASTEWATER
TREATMENT
SECTION GENERAL ARRANGEMENT
08
WASTEWATER
TREATMENT
PIPING PLAN GROUND FLOOR
09
WASTEWATER
TREATMENT
PARTIAL PIPING PLAN GROUND FLOOR
10
WASTEWATER
TREATMENT
PIPING SECTIONS AND DETAILS
11
WASTEWATER
TREATMENT
PIPING SECTIONS AND DETAILS
12
RECORD
DRAWING
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PROJECT NO.
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QUENCH and
PRE -SCRUBBER
900-1060 GPM
r GPM MAX (PLC TIMED
MULTIPLE TIMES/DAY
SIDE HILI
SCREEN
(1)
1060 GPM
5625 Ib/D (UMG)
SIDE HILI
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SIDE HILT
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DEFOAMER 600 1900 GPM 600-1900 GPM
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6360lb/D (UMG) & 6912 Ib/D UMG CENTRIFU E
FEED PUM #1
BUNKER
20 TO 35 GPM
NOTES:
(1) UMG= Old LOADING info from United McGill
and UMG WESP Project Team; NOT ACTUAL
35 TO 65 GPM 150-350 GPM CAUSTIC FLUSH
FROM WESP
(ESTIMATED CONDENSATE) 3 MINUTE FLUSH EVERY HOUR
735 IbID (UMG) PLC CONTROLLED TURBOSONIC WESP
YVSA
YADKIN VALLEY
SEWER AUTHORITY
GPS: LAT. 36.255235
LONG.-80.788737
SEWER LIFT
STATION EL13901
84 GPM CAP.
(60,000 GPD MAX.)
(SEE URS PROJECT 31829771)
kCID PUMP
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TANK
SHUT OFF
PRIMARY SETTLING VALVE
WESP BLOW DOWN \_FLOATIP
BAFFLE
440,000,
RECORD
DRAWINGS
WET
OPEN
NORM. CLOSED
NOTES:
1. AECOM DOES NOT GUARANTEE THE ACCURACY OF THE RECORD
DRAWINGS.
2. LOCATIONS AND INFORMATION SHOWN BASED UPON GIS DATA,
DATA PROVIDED BY WEYERHAEUSER NR COMPANY, AND SURVEY
CONDUCTED BY BIG EAGLE SURVEYING, APRIL 2013.
175 GPM
CONTAINMENT
DRAIN &
WASH SUMP
SURGE
TANK
4800 GAL.
WORKING VOL.
STORMWATER FROM
CONTAINMENT
NORM. CLOSED
STORAGE
POND
420,000 GAL.
PUMPS
(2 )
BUNKER
SOLIDS
APPROX.
8-25 Yd/D
20-140 GPM
OVERFLOW (CLEAN)
WATER
500 GPD COOLING
TOWER BLOWDOWN
SCUM
ILATING
CLARIFIER 600-1900 GPM
401 mg/I (UMG)
1327 Ib/D (UMG)
Kb7[�1�Si[c7F
NORM.CLOSED
DRAIN 600 GPM
APPROX.
25-300 GPM
GAPPROX.
125PM WASTE WATER
25 GPTREATMENT PHASEI
60,000 GPD MAX EL13904 DAF/PRESS
rDAF
SEE DWGS
FILTRATE 0151-105-56110-D0001-0001
0151-105-56110-D0002-0001
WASTE WATER PRESS WASH
TREATMENT PHASE II
EL15911 PRE-TREATMENT TO CLEAN WATER TANK
SEE DWGS RECIRC, SUMP or CLARIFII�
0151-105-56110-D0001-0001
0151-105-56110-D0002-0001
R.O. FILTRATE
PURIFIED WATER REJECT/FLUSH
TO CLEAN WATER TANK TO HOLDING TANK
OFF -SITE DISPOSAL
SELECT VALVE FOR
WASTE OR FRESH WATER
NORM.OPEN NORM, CLOSED
377 GPM MAX (PLC TIMED
MULTIPLE TIMES/DAY
900-1060 GPM
WESP HOT FLUSH
EXCHANGER
10-60 GPM @ 110-210 F
CLEAN WATER
STORAGE
10,000 GAL.
WORKING VOL.
HEATED
WASHWATI
TANK
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LEAN WA ER w
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PUMP ,
SLUDGE
STORAGE #1 '
TANK
1400 GAL. 0
WORKING VOL. WESP
QUENCH
PRE -SCRUBBER
SL3 '
BLOW PUMPS 900-1060 GPM
OVER DOWN (2)
FLO� PUMP
500 gal BACK FLUSH C1 M78
WATER
BD4
I
1
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100 - 250 GPM CAP.
Z FM (28,800 GPD MAX.)
~- GPS: LAT. 36.254372
LONG.-80.786614
PS: LAT. 36.254264
LONG. 80.785199
100 - 200 GPM CAP. ;
FM (11,000 GPD MAX.)
SANITARY
PUMPING '
STATION
1
1
AR950004
1
(SEE DWG-D260P-BEK-024-00) ;
300 GPM (4 MIN./HOUR) = 28,800 GPD
PUMP
CAUSTIC TANKS
KOH @ 45% sol.
2 X 1500 GAL
377 GPM MAX (PLC TIMED
MULTIPLE TIMES/DAY
WET
STORAGE WELL
PUMP
POND
MAKE-UP
WATER
840,000 GAL. POND
840,000 GAL.
1
I
1
4
1
1
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1
------------------------------ P--------1
----------------------------------------------------------------------- PUMP
REFERENCE DRAWINGS
REV.
REVISION
D700E-SBE-007
SANITARY PUMP STA, ELEC PWR
1
REMOVED CENTRIFUGE FEED PUMP #2
D70OC-SBE-013
SANITARY PUMP STA, CIVIL
2
REV FLOW UPDATE, AS -BUILT FOR TURBOSONIC ESP EL07902
D7OOC SBE-014 &015
SANITARY PUMP STA, CIVIL
3
ADD SEWER EL13901, WWTP EL13904 PH-2 TREATMENT EL15911
D70OP BEK-024 & D262P—BEK-025
SANITARY PUMP STA, SITE PLAN
—
4
ADD BLOWDOWN FM & YVSA FM COORDINATES
D262M WEY-045
E262P—WES-001 & 002
E262P WES-005
E262P—WES-008
WESP PUMP LOCATION
5
UPDATE PER INSTALLED—YVSA/BLIND TO SLUDGE TANK
PIPING LAYOUT, FANS/ESP AREA
G
WO #165987
PIPING LAYO, FANS/ESP AREA
H
AS BUILT
PIPING LAYOUT
0
AS BUILT
250 GPM
8
SPRAY
FIELDS
21 ACRES
SAFE FROM THE START
PROJECT NO.
ELKIN - NC150
WESP
DATE
BY
APP.
WEYERHAEUSER CONFIDENTIAL
12/18/07
DMH
NH
PREY. DWG. NO.
SIMONS 004-10-001
DRAWN SIMONS EA DESIGN SIMONS EA
BLOCK FLOW DIAGRAM
WET ESP EFFLUENT TREATMENT SYSTEM
04/06/11
KRC
KRC
KRC
----
03/29/18-KRC
-- --
-5/30- -/18
1/20/97
KRC
KRC
---
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MINS EA
— 8/------ 26/92--
DA
DATE
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DATE /Gz
92
DATE 9/11/9?
DATE
MILL No. D262PID-SIM-001
REV.
10/19/99
9/17/07
FAP
DMH
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,
SHT. SIZE
22" X 34"
SCALE
NONE
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11600 East hardy Road Phone: [phone]
Houston, Texas 77093 FAX: [phone]
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DRAWINGS.
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DATA PROVIDED BY WEYERHAEUSER NR COMPANY, AND SURVEY
CONDUCTED BY BIG EAGLE SURVEYING, APRIL 2013.
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PROJECT NO.
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THIS DRAWING HAS NOT BEEN PUBLISHED AND IS THE SOLE PROPERTY OF TOLERANCE UNLESS OTHERWISE NOTED:
ASHBROQK CORPORATION, AND IS LENT TO THE BORROWER FOR HIS USE BREAK ALL SHARP EDGES
ONLY. IN GONSIDETUTRDN OF THE LOAN OF THIS ORAWING,THE BORROWER
FRACTIONAL - t T 32'
PROMISES AND AGREES TO RETURN IT UPON REQUEST AND AGREES THAT IT DECIMAL . a t .03
X. - 1 .1. .XXX - 1 .015
SMALL NOT BE REPRODUCED. COPIED. LENT OR OTHERWISE DISPOSED OF ANGLES - t 1/2'
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FOR WHICH IT IS SPECIFICALLY FURNISHED. ALL DIMENSIONS IN INCHES.
NO. I OTY. I PART NO.
JET nr rnvvcv WALL j 1 6 Aslibrook Ci myworat ion
2 G 97 DATE 6 .r �, WEIGHT N/A 11600 East Hardy Road
APPROVED NEXT Ass N A Houston, Texas 77093
Phone: [phone]
v. DATE TUSTOMER FAX: [phone]
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TITLE BELT PATH DIAGRAM
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MD9703RO.DWG MD970003
1. AECOM DOES NOT GUARANTEE THE ACCURACY OF THE RECORD
DRAWINGS.
2. LOCATIONS AND INFORMATION SHOWN BASED UPON GIS DATA,
DATA PROVIDED BY WEYERHAEUSER NR COMPANY, AND SURVEY
CONDUCTED BY BIG EAGLE SURVEYING, APRIL 2013.
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ASHBROOK WINKLEPRESS
OPERATIONS & MAINTENANCE MANUAL
TABLE OF CONTENTS
Descry Section
Trouble Shooting Charts
1.0
General Information
2.0
General Mechanical Description
2.1
General Process Description
2.2
General Arrangement Drawing
2.3
Receiving Section
3.0
Handling Instructions
4.0.
Storage Instructions
5.0
Installation Section
6.0
Mechanical Start -Up Procedures
7.0
Process Start -Up. Procedures
8.0
Daily Operations
9.0
General
9.1
Pre -Operation
9.2
Operation
9.3
Normal Shut -Down and Clean -UP
9.4.
Emergency Shut -Down
9.5.
Maintenance Procedures
10.0
General
10.1
Daily Maintenance
10.2
Weekly Maintenance
10.3
Monthly Maintenance
10.4
Semi -.Annual. Maintenance.
10.5.
Frame and Coating
10.6
Rollers
10.7
Bearings.
10.8
Steering Assembly
10.9
Tensioning Assembly
10.10
Hydraulic Power Unit
10.11
Feed Assembly
10.12
Gravity Drain
10.13
Wash Stations.
10.14.
Scrapers
10.15
Drive Unit
10.16
Dewatering Belts
10.17

Description Section
In -line Mixer
10.18.
Lubrication Section
11.0
Lubrication Schedule
11.1
Lubrications Cross Reference
11.2
Spare Parts
12.0
Spare Parts List
12.1
Ordering Information
12.2

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ASHBROOK WINKLEPRESS®
fidd'IN
2.1 GENERAL MECHANICALDESCRIPTION !U= }
2.1.1 INTRODUCTILON The Ashbrook Winklepress® leads the dewatering market in
Percentage of cake solids and throughput. Ashbrook manufactures the Winklepress® from
quality materials with tough, corrosion -resistant coatings, which results in years of
dependable service atld minimal maintenance.
2.1.2 MECHANICAL 12ESCREnION For description purposes, the Winklepress(D
is broken down into functional groups as indicated below. While most materials can be
found in the description, please reference the Materials of Construction Section for the
exact materials supplied.
A.
Main Frame
B .
Rollers
C .
Bearings
D.
Steering Assemblies
E.
Tensioning Assemblies
F.
Hydraulic Power Unit
G.
Feed System
H .
Gravity Drain Section
I.
Wash Stations
I.
Scrapers
K.
Drive Train
L.
Dewatering Belts
M.
In -Line Mixer
a. Main Frame: A semi -rigid, self-contained, steel structure consisting of side
frames and cross members. The frame resolves the dewatering pressures into vertical loads
which are transferred to the foundation. While the frame maintains the structural integrity
of the machine, it relies on the foundation to hold the machine level and preserve the
alignment-
b. RORM: Fabricated assemblies, typically of double end- plate, stub shaft
construction, which provide a bearing surface for the belts. The roller shafts (journals) are
machined on both ends to accept the roller bearings. All rollers are coated externally for
corrosion resistance; perforated rollers are also coated internally. The rollers may be any of
the following types:
(1) Dandy Roller: Perforated roller with internal scoops to channel captured
filtrate away from the sludge.
(2) Drive Roller: typically covered with 1/4" Buna-N rubber, used to pull
the dewatering belts. Normally, one per belt.
(3) PlainRoller any non -perforated roller of varying diameter with the job
specified covering, typically nylon. Used in the steering and tensioning assemblies, as
Pressure rowers, nip rollers, or as idler rollers to change belt direction. Nip roller(s)
function by placing additional pressure on the sludge at the end of the high pressure zone.
In some processes, this will increase the final cake solids.
c. Bearines: Support the rollers on both ends and maintain parallel roller alignment.
The cast iron bearing housing is split horizontally to allow access to the bearing without
disturbing the bearing alignment. All bearing housings incorporate a button -head grease
Revised 4/95

fitting for maintenance purposes. The steering bearings are cylindrical bore, cylindrical
roller bearings. All other bearings are cylindrical bore, spherical roller bearings. The
bearing shaft seal is a triple seal comprised of the labyrinth, and elastomer face seal and
quad ring. For additional moisture protection, the seal features a shaft mounted splash
guard.
d. n' Assembly: Monitors the position of the dewatering belts and makes
adjustments to maintain belt alignment in the center of the machine. The Winklepress® has
one steering assembly, comprised of a steering roller and a hydraulic positioning unit, per
belt. The assembly works by moving one end of the steering roller so that the belt tracking
perimeter is smaller on one side of the machine. The belt responds to this change in
tracking perimeter and moves to that side of the machine. The components of the steering
assembly are:
(1) Hydraulic Positioning' : The unit has a belt position sensing paddle
that is constantly in contact with the belt. This paddle sends a signal to a hydraulic valve
which adjusts the flow of hydraulic fluid to a hydraulic steering cylinder. As the cylinder
responds, the steering roller position is altered. The stainless steel sensing paddle has a
ceramic wear plate to protect the belt edge.
(2) ,Steering Roller: The steering roller is a plain roller with steering
bearings. The bearing housings are attached to swivel plates to accommodate the roller
movement.
e. Tensionine Assembly: Consists of hydraulic cylinders, a rack and pinion
alignment system and a two -position, four-way control valve. For optimum performance,
both belts on the Winklepress® are tensioned identically. The belts may be tensioned or
retracted at the control valve on the belt press, however the amount of belt tension is
regulated at the pressure valve on the hydraulic power unit. The individual tensioning
components are as follows:
(1) Hydraulic ,ylinders: responds to changes in pressure from the
hydraulic power unit and pushes or pulls on the rack (lower belt) or pinion (upper belt) to
decreasetincrease belt tension. There is one hydraulic cylinder on each end of both
tensioning rollers.
(2) Rack od &ion Syitem: Ensures perfect parallel alignment of the
tensioning rollers. The bearing pedestals which support the upper bearing tensioning roller
bearings are attached to a freely rotating shaft which spans the machine width. There is a
pinion gear attached to each end of the shaft. The two pinions ride on two racks which are
attached to the main frame in perfect alignment. This system will not allow one side to
advance faster than the other side and maintains absolute alignment when the system is not
moving. The lower belt tensioning works under the same principal except that the rack
moves and the pinions and shaft are fixed in position and only allowed to rotate. The
system maintains equal belt tension across the entire width of the belt.
(3) Control Valve: A two -position, four-way valve which regulates the
flow of hydraulic fluid to the hydraulic cylinders in the tensioning and steering assemblies.
The hydraulic lines connecting the valve to the tensioning cylinders have independent
shutoffs to isolate the individual belts.
Revised 4/95

f. Hydraulic PowUnit: a self contained unit which provides all hydraulic power
for operation of the steering and tensioning assemblies. The unit consists of a 20 gallon
reservoir with externally mounted oil level, temperature and pressure gauges. The pressure
gauge is dual scaled for hydraulic pressure in pounds per square inch (psi) and dewatering
pressure in pounds per linear inch (pli). An externally mounted motor powers the internal
hydraulic pump. The hydraulic pressure is adjusted by regulating the pressure relief valve
on the unit. Hydraulic oil is filtered through the externally mounted return filter and
through an internal filter on the suction side of the pump. The reservoir tank has a drain
valve for maintenance purposes.
Depending upon the specific site installation, a multi stage hydraulic unit may be supplied.
This unit contains one motor which drives one or more pumps. The additional pump(s) are
used in conjunction with flow splitting devices to provide independent belt tension circuits,
belt steering as well as a separate circuit for the optional nip roller(s). The nip roller exerts
additional pressure on the sludges at the end of the pressure zone.
g• Feed A=Mhiy: Stainless steel chute which distributes the flocculated sludge
across the belt to begin gravity dewatering. The feed chute has a standard ANSI flange for
connecting to the sludge feed line.
h• : Consists of the horizontal drainage grids, a vertical
wedge section, the Ashbrook patented chicanes, the drainage trays and piping, and the
sludge restrainers.
(1) Drainage, Grids: Series of polyethylene strips arranged in a chevron
pattern which support the dewatering belts. The strips are installed on stainless steel grid
above the drainage trays. The polyethylene provides a low friction wear surface for the
belts.
(2): Two polyethylene plates oriented vertically with the
larger opening at the top. The sludge flows from top to bottom and is dewatered by gravity
and low pressure in this area as the sludge is mildly squeezed between both belts by the
plates. For process flexibility, both the top and bottom openings are adjustable. The
filtrate drains through perforations in both plates where it is diverted to avoid rewetting. A
flexible seal secures the sludge from being squeezed out between the plates.
(3) Chicanes: Ashbrook Corporation's patented plows which turn the
sludge and provide clear openings for the free water to drain into the drain pans. The
chicanes pivot independently on the support bar which allow them to float directly on the
belt and ride smoothly over the belt seam. This minimizes belt wear and prevents
obstructions from blocking the sludge flow.
(4) Drainages: Assortment of stainless steel pans which collect the
filtrate for piping to the machine sump. The piping is designed to be self -venting to
provide maximum drainage flow.
(5) Sludge Restrainers: stainless steel guide which prevents sludge from
running off the sides of the dewatering belts. The sludge restrainers are fitted with a
neoprene strip at the bottom to maintain the seal between the belt and the sludge restrainer.
Revised 4/95

i. )ash Stations: Two slotted stainless steel boxes containing the wash tube. The
wash tube generates an overlapping spray pattern from the jet nozzles to blast embedded
and surface particles from the belt. The wash tube has an internal brush for cleaning the
nozzles while the machine is running. The wash station entry and exit slots are covered
with neoprene seals to protect the belt and to prevent overspray from the wash box. Each
wash box is drained individually.
j. r : Steel assemblies fitted with polyethylene blades which
remove the dewatered sludge cake from the dewatering belts. The scrapers are spring
tensioned for pre -load adjustment.
k. Drive Train: Powers the Winklepress® by turning the drive rollers which pull
the dewatering belts through the press. The drive train components are the two motor
driven helical bevel gear reducers connected in parallel to one variable motor speed
controller. See the Drive Section of this manual for more detailed information on the drive
motors and gear boxes provided with this unit. The parallel wiring situation ensures
adequate speed matching of the motors leading to properly matched roller rotation. The
drive train receives its initial input from a variable speed drive unit. This allows the speed
of the belts to be varied from approximately one to six meters per minute. Belt speed will
depend upon the type of dewatering process desired. The drive motor input shaft power is
reduced and its torque amplified in the primary speed reducer. This is a self-contained
helical bevel gear box with its own splash lubricated system.
1. Dewatadng Belts: Polyester woven mesh joined by a stainless steel clip to form
an endless band.
m. In -Line Mixer: Self-cleaning variable orifice venturi mixer used to condition the
sludge prior to dewatering. The mixing energy may be varied independently of the
flocculation by moving the mixer arm and counterweight. This independent adjustment
results in the lowest polymer usage of any belt press on the market.
Revised 4/95

ASHBROOK WINKLEPRESS®
M-M*W
2.2 GENERAL PROCESS DESCRIPTION
2.2.1. Introduction: Ashbrook's dewatering equipment is designed for
use in municipal, industrial or other specialized applications where removal of a liquid
(usually water) from a solid -liquid suspension, sludge, is desirable. The Winklepresse
Belt Filter Press does this through the use of two porous belts which allow both gravity
and pressurized dewatering. In the gravity stage, the sludge is allowed to thicken and most
of the filtrate, water, is removed. During the pressure filtration stage, the sludge is also
exposed to shear forces which greatly increase filtration. The filtrate removed is captured
and piped to the base of the machine. This water, which has a very low solids content due
to the superior capture rate of the Winklepress®, is often drained back to the head of the
plant. In some instances, the filtrate may be recycled as belt wash water. The discharge of
the machine is a friable cake with a greatly increased solids content.
2.2.2. ewatering aocess., Prior to filtration, the sludge must be conditioned to cause
solid particle agglomeration or clumping. This process, called flocculation, is
accomplished by injecting a polyelectrolyte, or polymer, into the sludge. Since most
sludges are charged, it is important to select the proper type of polymer to neutralize the
charge. As the nature of flocculated sludge controls to some extent the dewatering
characteristics of that sludge, polymers of varying charge, strength, and molecular weight
should be tested. The Ashbrook laboratory can assist by analyzing individual slurries and
recommending the optimum polymer and dosage. Along with the type of polymer, mixing
energy and retention time play a major role in the flocculation process. For this reason, the
Ashbrook system of polymer injection and in -line mixing is designed for maximum
flexibility. Ashbrook typically supplies one in -line variable orifice mixer and polymer
injection ring per machine. We recommend that three polymer injection locations in the
sludge feed line be established. The locations should be selected to allow 15, 30, and 45
seconds retention time before the polymer sludge mixture enters the Winklepresse. These
Iocations allow the mixer/polymer injection ring to be relocated easily should more or less
retention time be required for optimum dewatering. To remix flocculated sludge is counter-
productive, so the unused locations should be fitted with spool pieces of nominal size.
The flocculated sludge is discharged from the feed line onto the Winklepress® through a
feed chute. This chute spreads the sludge across the entire machine -width to allow
optimum gravity dewatering. During the dewatering process, sludge is conveyed on a
porous weave belt. The belt allows the free water to pass through where it is captured by
drain pans and piped to the machine base. The sludge is prevented from running off the
sides of the Winklepress® by sludge restrainers and rubber seals. As the sludge is
moved through the gravity section, it is turned over by A.shbrook's patented Chicanes.
These plow -like devices greatly increase the gravity dewatering by clearing places for the
water to drain as they turn the sludge mass. At the end of the gravity section, the sludge is
a loosely structured cake ready for the pressure dewatering.
The first half of the pressure section is the vertical wedge section. At this point the two
belts begin to converge, compressing the sludge . The first roller encountered in this stage
is Ashbrook's Dandy Roller. This perforated roller has internal scoops to channel captured
filtrate away from the sludge. As the belts travel past the Dandy Roller, they take an S-
shaped path around rollers of progressively decreasing diameter. This increases both the
pressure and the shear -action to the sludge. The group of smaller diameter rollers is the
high pressure section of the dewatering process. The shear -action, in this section, turns

the sludge mass within the belts exposing the wet inner cake to the belts and expelling the
free water. At the end of these rollers the belts separate and the sludge cake is discharged
from the machine.
The belts continue past scrapers which remove any residual cake and prepare the belts for
cleaning. The belts are washed in separate washboxes which remove any particles that may
have embedded in the porous belt. The belts must be continually cleaned to prevent belt
blinding and a loss of dewatering ability. The clean belts exit the wash boxes to begin the
process again.

ASHBROOK WINKLEPRESS®
511"0
3.0 RECEIVING. Thoroughly inspect the equipment before accepting shipment from the
transportation company. If any item on the Bill of Lading is damaged or missing, ensure
an annotation is made on the Freight Bill or Express Receipt. If any concealed damage is
discovered after unloading, notify the transportation company and request an inspection.
Ashbrook inventoried and packaged the spare parts required for your order prior to
shipment. To ensure inventory accuracy, we request the package labeled "Spare Parts" not
be opened until the Ashbrook Service Technician arrives. If the box is opened prior to our
arrival, Ashbrook will not assume liability for any missing spare parts.
Ashbrook will assist your efforts to collect claims for loss or damage in transit.
Please notify Ashbrook within three (3) working days of delivery should there be any loss
or damage. Ashbrook's assistance does not relieve the transportation company of any
responsibility for reimbursement on your claim and in no instance assumes liability on the
part of Ashbrook for the claim.
Claims for loss or damage in transit do not alter the payment terms for your order
and payment should not be withheld or delayed because of a claim.

ASHBROOK WIMKLEPRESS®
f
4.0 HANDLING INSTRUCTIONS. The press should be lifted using four lengths of
chain or cable connecting to the lifting lugs provided on the frame. Ashbrook recommends
the chains be at least eight feet in length to prevent side frame distortion while lifting. All
chains and cables should be sized to handle a rated working load of one fourth of the static
weight of the machine as shown on the General Assembly drawing in this manual. If
additional information is desired, please contact the Ashbrook Engineering or Service
Department.
4.1 Care should be taken that the lifting forces are transmitted vertically to the
side frame only and that precautions are taken to prevent overload to the machine or the
lifting equipment due to acceleration, deceleration or shock forces. The machine should be
lowered carefully to rest on a level surface with its weight evenly distributed to the
supports.
4.2 The Hydraulic Power Unit should be Iifted from the bottom only, preferably
using a fork lift or by properly slinging it around the reservoir. Care should be exercise
during lifting to avoid damaging the exterior valves, fittings, motor, etc.
4.3 Lose ship items such as the belts, in line mixer, booster pumps, etc. will be
consolidated and crated for shipment. All crates should be lifted from.the bottom only
using a fork lift or slings.
AQRT

ASHBROOK WINKLEPRESS®
M�ll
5.0 STORAGE. Ashbrook recommends indoor storage for all items, however we
recognize this may not be possible. If limited indoor storage is available, we recommend
storing the hydraulic power unit and the loose ship items indoors. Additionally the
following steps should be taken for all storage locations:
5.1 Store the press in a level position supported on wooden dunnage. The
cantilevered end should be braced as illustrated below to prevent the machine from
accidentally tipping in that direction.
5.2 Completely cover the press with a well secured waterproof tarpaulin in an
area free of extreme temperatures, moisture, shock and vibrations.
5.3 Do not store items on top of the press.
5.4 Periodically inspect the roller spindles, gears, etc for rust. Keep these items
well Iubricated to prevent rusting.
5.5 Bearings are greased when they leave the factory. No additional greasing is
necessary for storage.
5.6 The primary and secondary gearboxes are shipped completely filled with
oil. No additional oil is required for storage. However, they must be drained to the proper
level before starting.
5.7 The hydraulic power unit and drive motor (if shipped loose) should be
stored in a clean, dry area protected from extreme temperatures, moisture, shock, and
vibration.
5.8 Rotate all rollers two or three revolutions by hand every thirty (30) days.
5.9 The box labeled "Spare Parts" should be stored unopened.
IPPOFM

ASHBROOK WINKLEPRESS®
LW
"F1 p
. �
iJGEMMISC m8&PARAMM `
6.0 INSTALLA-TION INSTRUCTIQNS
6.1. Ste: The proper design and construction of the foundation, sump, piping,
pumps and other ancillary equipment operated with the Winklepress® is the responsibility
of the owner, engineer or contractor unless arranged otherwise at the time of purchase.
These instructions are intended as a guide based on sites with configurations similar to
those recommended by Ashbrook. Since they are general, some modifications may be
required to solve your unique requirements. Should assistance be required, please contact
Ashbrook's Engineering or Service Department.
6.2 Installing the Mpkiegressle:
6.2.1 Study applicable plans to verify location of press. Confirm the machine
orientation in this manual matches the hook up locations in the plans including wash water,
electric, sludge feed, and polymer.
6.2.2 Verify cast in place anchor bolt locations from Sump Layout Drawing. If
anchor bolts are expansion anchors, they will be installed after press is set on piers.
6.2.3 Lift press according to Handling Instructions and carefully set it in place.
CAUTION: Ensure lifting safety is observed during all boisting operations.
6.2.4 Loosely secure anchor bolts. If expansion anchors are to be used:
a. Mark their Iocations while Winklepress® is in place.
b. Remove Winklepress® following Handling Instructions.
c. Drill and install expansion bolts.
Note: Drilling the anchor bolt holes while the WinklepressO is in place could damage
the frame's protective coating or cause other alignment problems.
d. Replace the Winklepress® following Handling Instructions.
e. Loosely secure the anchor bolts.
6.2.5 Level the Winklepresse:
a. Using a precision level, check the following four rollers for level across
the width of the machine; both tensioning rollers, upper drive roller, Dandy (perforated)
roller .
b. Shim the Winklepress® around the anchor bolts until all of the above
rollers are level.
Note: Do NOT shim any roller. Shimming the roller could cause premature bearing
failure or belt alignment problems, and void the Ashbrook Cornoration warrant„
c. Tighten the anchor bolts.

6.2.6 Verify rollers remained level by checking the four rollers again. Check
machine for level lengthwise by taking an elevation at the four corners.
6.2.7 ReleveI the machine as required.
6.2.8 Grout the machine as applicable using a non shrink, non metallic grout.
6.3 Hook TJp Hydraulic , Power Unit:
6.3.1 Locate the unit so that all gauges are visible and the unit is accessible for
operation and maintenance.
6.3.2 Ashbrook recommends securing the hydraulic power unit to the floor using
expansion bolts.
6.3.3 Connect the hydraulic unit to the press. If this requires more than the two
sections of ten foot flexible hydraulic line provided by Ashbrook, the additional hydraulic
lines will be supplied by others. The additional lines should be a minimum of 3/8 inch
diameter rated for 1000 psi.
�voa� e: ine nyarauuc power umt is snipped ailed with oil and ready for operation. This
ail level should not be changed prior to operation.
6.4 Qnnect WasbMter: Water should be provided to the wash boxes at 85 psi and
the following flow rates: Size 1, 58.5 gpm; Size 2, 82.5 gpm; Size 3, 100 gpm. If the
water pressure or flow is not sufficient for the above requirements, then a booster pump is
required. The wash water connection will be two inch diameter Schedule 80 PVC unless
otherwise specified. Ashbrook recommends a ball valve be installed prior to any booster
pump required and a pressure gauge be installed prior to the press to verify pressure
requirements.
6.5 Conact Sludgc &ed Line: The sludge feed line will be connected to the
Winklepress® feed chute as shown on the General Arrangement Drawing in this manual.
Use a flexible connection to allow for adjustment of the feed chute. The feed chute is
supplied with a standard ANSI 150 lb raised face flange unless otherwise specified. On
Size 1 & 2 machines, a four inch diameter feed chute will be supplied (standard, unless
otherwise noted). The Size 3 Winklepress® has a six inch diameter feed chute inlet.
Ensuring the sludge is fed evenly across the belt width is critical to the performance and
maintenance of the belt press. Because of this, Ashbrook recommends eight feet of straight
feed piping prior to the feed chute. Additionally, sharp turns in the feed line should be
avoided by using long radius elbows.
6.6 Install In Line Kizer: The Ashbrook In Line Mixer should be installed initially at
the location that will allow 30 seconds retention time or as recommended by Ashbrook's
Process Engineers. Ensure the directional arrow on the mixer points in the direction of the
sludge flow. The polymer injection ring should be installed between the inlet flange of the
mixer and the sludge feed pipe. Connect the injection ring to the splitter manifold via four
lengths of clear hose. Connect the splitter manifold to the polymer system according to the
polymer system manufacturer's instructions.
6.7 E er 'cal Hook -Ups: Electrical interconnection of the Winklepress is always
through a dedicated control panel. It is often the case that all required motor starters and or
drives are integrated with the operating logic into a single panel. In this case, it will only be
necessary to perform all interconnection wiring between the press and the panel as

described by the terminal strip diagrams found in the as built control panel drawings. It is
also possible that the control panel may contain only operating logic and all starters are at a
motor control center or that other equipment must be interlocked with this panel. Once
again, the as built drawings will provide interconnection guidance. On the Winklepress, all
control wiring is terminated in the junction box on the machine. To complete the
installation, the following connections are required:
WARNING: Electrical connections should only be attempted by a
qualified electrician. All electrical work must be In compliance
NEC, NEMA, OSHA and other local codes. Serious personal Injury,
fatalities, or equipment damage could result as a result of incor
electrical connections.
6.7.1 WinkleFre&A x• The machine is shipped pre -wired. The
installing contractor is responsible for interconnecting the junction box and the control
panel as indicated on the as -built electrical drawings.
6.7.2 Wink1Qpres0 Drive Unit: Consult the Drive Section of this manual for the
electrical requirements of the specific drive motor provided. The connection will be made
at the junction boxes on the machine's drive motors.
6.7.3 i w : The motor is a 230/460 volt, 60 Hz, 3 phase, 1.5
horsepower unit unless otherwise indicated in the hydraulic unit section of this manual.
Electrical connection will be at the motor junction box. The connection information is on
the inside cover of this box. The hydraulic unit will also have two pressure switches inside
the tank These are wired to a separate junction box on the lid of the tank. The connection
information is inside this box.

ASHBROOK WINKLEPRESS©
0
W
7 I I p;
7.L General: Prior to attempting dewatering for the first time, the Winklepress® must be
inspected and prepared for operation. This section addresses the procedures which will
prepare the machine for operation.
7.2.hChanicai Check Out;
7.2.1. Visually inspect anchor bolts and verify they are tightened.
7.2.2. Verify the machine is level.
7.2.3. Inspect the rollers:
a. Verify rollers are level across the machine width.
b. Check for cleanliness. Remove any dirt, grease, etc.
c. Turn each roller by hand two or three revolutions.
Note: The seals should drag slightly and the drive rollers should not turn.
d. If any roller turns roughly or sticks, inspect the roller for external
obstructions. If no obstructions exist, disassemble the bearing housing and inspect the
bearings. If damaged, notify Ashbrook for repair or replacement.
Note: The bearing housings are matched sets. Ensure they are riot mixed up if removed.
e. Inspect the roller coatings. All coatings should be intact.
7.2.4. Inspect the gravity drainage grids:
a. Grids should be level and free from any sharp edges or protrusions.
b. Grids should be free of embedded materials and all bolt heads should be well
below plastic wear surface.
c. Sludge retainers should be in place and the rubber seal should be intact.
Remove any sharp edges.
d. Chicanes blades should be resting on the grid. No metal portion of the
chicane assembly should be touching the grid.
e. Verify the scrapers pivot freely and that the plastic blades are not chipped,
cracked, or broken.
7.2.5. Inspect wash boxes and verify rubber seals are in place.
7.3. Electrical —Check
—Check Ont:
WARNING: Electrleaf connections should only be checked by a
qualified electrician. Failure to follow federal, state or local
codes could cause severe personal injuries, fatalities or severe
equipment damage.
7.3.1. Hydraulic Power Unit: Bump the motor circuit to ensure motor is turning in
the correct direction.

CAUTION: Alarms and sensors are on the machine to protect personnel and the
equipment. Operating the machine with sensors not functioning properly places the
operator and equipment in danger.
7.4. Hydraulic System Cbeck
7.4.1. Verify hydraulic lines between hydraulic power unit and the Winklepress® are
in place.
7.4.2. Put the control valve on the Winklepress® in the retract position.
7.4.3. Set the hydraulic unit for the initial run by opening the pressure relief valve.
Rotate the valve control knob counter clockwise until you feel the valve stem unseat from
its spring.
7.4.4. Energize the hydraulic power unit. The pump should take between 10 and 30
seconds to increase pressure which will register on the pressure gauge. The pressure
should be in the range of 100 to 150 prig.
Note: If the pump has not picked up pressure within 30 seconds, shut the pump down
and check for correct pump rotation and fluid level.
7.4.5.With the pumps operating, turn the valve knob until the pressure is in the range
of 300 to 350 psig. Lock the pressure regulator lock nut at this setting.
7.4.6. Check the tension circuit:
a.Place the control valve on the Winklepress® in the tension position.
b.Check the belt press and the hydraulic power unit for leaks.
c. Ensure both tension rollers are moving towards their fully extended
positions. If the rollers are not extending, the hydraulic lines from the hydraulic power unit
are reversed. Shut down the unit, reverse the connections and restart the hydraulic power
unit.
Note: Each tension circuit has a separate in line shut off valve so that the circuit may
be operated independently during maintenance operations.
d. Cycle both rollers through the tension/retract cycle several times to
ensure they function correctly. Verify that the rollers do not contact any portion of the
frame during their travel. If contact is made or imminent, reverse the travel of the roller and
clear the obstruction.
Note: The pressure gauge will show a pressure drop of 50 to 100 psig during travel of
the tension roller. This lower pressure minimizes the force if an obstruction is hit and
cushions the loading at the and of the stroke.
7.4.7. Steering Circuits: Check the following items on both steering valves and
hydraulic positioning units:
a. Inspect sensing paddle for damage, and freedom of movement. If
movement is stiff, notify the Ashbrook Service Department-
b. Manipulate valve by manually moving sensing paddle off center in one
direction. The hydraulic positioning unit should move fully in one direction in response to
the sensing paddle. Move the paddle off center in the other direction and note the
movement of the hydraulic positioning unit in the other direction.

7.4.8. ** Nip Roller: (option) If used with your installation, verily that hoth
cylinders are operating correctly and uniformly against the bottom pressure; roller. The
hydraulic pressure for the nip roller should be initially set at I50 psi. The normal operating
pressure ranges are from 150 to 350 psi.
7.5. Nash Water: Inspect the following items:
7.5.1. Verify the wash water is being delivered to the wash boxes at 85 psig and at
the correct flow rates. If a booster pump is installed, ensure pump is functioning correctly.
7.5.2. Verify all valves in the water line are open.
7.5.3. Verify both hand wheels on the wash tubes are fully closed. Rotate completely
in the counter clockwise direction and then back fully in the clockwise direction. This
action rotates the brush inside the wash tube and cleans the spray nozzles.
Note: Do NOT over tighten hand wheel. This could damage the internal seals causing a
loss of wash water pressure.
7.6. De term B It Installation: The dewatering belts are very expensive and one
of the most easily damaged items on the Winklepress. Because of this, it is important to
know how to handle the belt prior to attempting installation.
7.6.1. Handling and Storage:
a. Always store belts in their protective wrappers or containers.
b. Do not smash, stack or store items on the rolled belts.
c. Do not allow the belt to become kinked because this could result in an
unusable seam.
d. Keep foreign substances off the belts as much as possible.
e. Never attempt dewatering until the new belt has been broken in
according to the instructions in this manual.
7.6.2, Belt t : Installing the dewatering belts can be done in a safe and timely
manner, however, it does present a situation where carelessness can cause injuries. To
ensure a safe operation, Ashbrook recommends:
a. Stop switches: Ensure location and operation of the stop switches for
the drive and hydraulic unit are known and that all switches function properly. Have
someone available to immediately stop the machine.
b. Remember that the belt moves slowly and can easily catch loose
clothing, hands, jewelry, etc. Remove jewelry and fasten clothes to protect yourself.
c. The hydraulic system also moves slowly, but with bone crushing force.
Do NOT place body parts between the moving machine parts.
WARNING: Failure to follow safety Instructions while installing
or servicing the dewatering belts can result In severe Injuries
or loss of limbs. Use extreme caution when working with the
belts.
7.6.3. Belt Installadon:
a. Lift chicanes off supporting grid by rotating their lifting handles.

installation. b. Loosen the upper and lower wash boxes to allow for the belt
c. Unwrap belts and record their serial number on the Belt Record Sheet.
d. Remove joining wire from the belt seam.
e. Position upper belt at the discharge end of machine and lower belt at the
tensioning end of the machine.
f. Begin feeding lower belt over the lower tensioning roller, the grid and
to the first pressure roller.
g. Ensure the belt is feeding square. Any kink or wrinkle in the belt must
be eliminated or the belt could be damaged when tensioned.
h. After straightening the belt, continue the belt through the pressure
rollers and down to the lower steering roller.
i. Carefully energize the belt drive and have it assist you in bringing the
belt around the lower steering roller, through the lower wash box, the lower idler roller and
back to the other end of the belt.
CAUTION: Ensure the belt is feeding without kinks or wrinkles. If a wrinkle develops
that cannot be straightened, back the belt out and start again. Failure to keep the belt
straight and square will cause kinks and prolonged operation of the kinked belt will
cause it to fail prematurely.
Note: The smooth side of the belt should face the sludge when installed. Failure to have
this side facing the belt will cause improper dewatering and premature belt failure.
The Ashbrook Corporation warranty does not cover belts installed incorrectly.
j. Join the two ends of the belt and thread the splice wire through the
loops. Ensure the thread wire does not miss any loops and catches each Ioop alternately.
Ensure the belt edges are in line and do not form a step.
the excess wire. k. Bend the wire into a loop and feed it back into the belt loops. Cutoff
1. Repeat steps F through K for the upper belt.
in. Tighten the wash boxes so that the neoprene seal just touches the belt.
n. Rotate the chicanes onto the belt.
7.7. ,Run In Period: New belts should always be broken in for about 30 minutes prior to
being loaded with sludge. This ensures the new belts track properly and pre -stretches the
belt. Always monitor the machine closely during this time. The process for belt run in is:
7.7.1. Install the new belts according to this manual.
7.7.2. Adjust the tensioning pressure to 300 psig.
7.7.3. Start the belt wash water flow and energize the belt drive.
7.7.4. Follow the chart below to increase the pressure during the break in cycle.
7.7.5. Lock the pressure control valve on the hydraulic pressure unit in place with the
jam nut at the end of the break in cycle.
7.7.6. Adjust the steering sensing paddles so the dewatering belts track on top of each
other and in the center of the machine.

Note: Fine adjustment of the steering circuit is best done with the belts moving.
7.7.7. Proceed to Process Start Up.

ASHBRQQK WINKLEPRESS®
.0 ERMOCESS START P:
8.1. General: Knowing how to safely operate the mechanics of the belt press is
important. However, knowledge of how the Winklepress® dewaters and how to achieve
the optimum performance from the press is what generates long term savings. The
procedures for process start up and optimization are covered in the following section.
8.2. Process Variables:
8.2.1. Sludge F : The amount of dry solids dewatered per hour, or throughput,
desired and the feed solids concentration determine the flow rate required for this process.
The belt press width is then sized to handle that particular flow. For a quick reference the
following municipal sludge feed rates can normally be handled at a feed solids
concentration of 1.5 to 3.0 percent:
a. Size 1 (1.0 meter dewatering width) - 0 to 70 gpm
b. Size 2 (1.5 meter dewatering width) - 0 to 110 gpm
c. Size 3 (2.0 meter dewatering width) - 0 to 140 gpm
8.2.2. Polymer: Sludge dewatering on a belt filter press is made possible to a great
extent through the addition of a polyelectrolyte or polymer to the sludge. The primary duty
of the polymer is to cause the sludge solids to flocculate. To do this, the polymer must
neutralize the sludge charge, cause a rapid desorption of the sludge particles which unbinds
surface water and cause the sludge particles to form chains or flocs along the polymer. To
accomplish the optimum dewatering, it is important to select the proper polymer type and
concentration.
a. Polymer: a polymer should be chosen which neutralizes the
sludge charge, and works within the pH range of the treatment plants process. The three
basic types of polymer are:
(1) Cationic: a positively charged polymer used with negatively
charged sludges. This is the most common polymer.
sludges. (2) Non-ionic: a neutrally charged polymer used with neutrally charged
charged sludges. (3) Anionic: a negatively charged polymer used with positively
b. RW,=gr Dosage: polymer should be injected into the sludge at the
minimum level required for dewatering. All non reacied polymer is wasted to filtrate and
therefore not cost or process effective. A process diagnostic chart is attached to help the
plant operators determine if too little or too much polymer is being used.
As a rule of thumb, polymer concentration should be in the 0.10 to 0.25 percent
8.2.3. BLWng line y,�: the force required to ensure polymer has fully dispersed
within the sludge feed to cause complete flocculation. The mixing: energy is adjusted by
moving the adjusting arm on the in line venturi mixer. Ashbrook recommends starting
with the mixer half open and then adjusting it as needed. The symptoms of insufficient

and excessive mixing energy have been included on a process diagnostic chart in this
manual for your use.
Note. Closing the mixer INCREASES mixing energy.
Opening the mixer DECREASES mixino eneray.
8.2.4. Flocculation Time: after the polymer has mixed with the sludge, a certain
amount of time is required for the flocculation process to occur. With too little time, the
flocs will be small and with too much time the result is large, clumpy flocs. Both of these
lead to reduced dewatering. For ideal dewatering, small strong flocs are desired. For
more flocculation time, position the in line mixer farther away from the feed chute and
position it closer for less time.
8.3. WinklelRreu&n
8.3.1. elt S=d There are two basic considerations with belt speed. The slower
the belt speed, the greater the effects of the pressure section which translates into increase
cake dryness. This works because as the belt slows, the cake trapped between the belts is
allowed to thicken which increase the shear -action produced by the pressure rollers.
Conversely, the faster the belt speed, the greater the process throughput (assuming sludge
feed rate is increased). The belt speed should be slowly adjusted until the optimal balance
between process throughput and cake dryness is acheived.
8.3.2. belt Tension: The belt tension should be set at 350 psig initially by adjusting
the pressure valve on the hydraulic power unit. Since the sludges vary from plant to plant,
the optimal pressure should be determined once the belt press is operating. An increase in
the belt tension will increase the shear action in the pressure rollers resulting in a dryer
cake. However, it could cause the negative effect of belt blinding or through the belts
which will result in an unacceptable amount of solids lost to filtrate. Ideally the pressure
should be just below the point where the belt is blinded.
8.3.3. Verticle j7Ved=: The verticle wedge section has adjustments on all four
corners. It is imperative that both sides of the wedge be adjusted evenly. The bottom of
the wedge should be set so that sludge does not fall out of the sides. The principle of the
wedge is to keep a constant hydrostatic head pressure on the sludge. The wedge is
adjusted by tightening or loosening the nuts which hold the spring tensioned wedge
section.
8.3.4. Belt Jae: The opening size and weave of the belt determine the dewatering
characteristics of that belt. the initial belt supplied by Ashbrook with your machine as
been selected based on our experience with processes similar to your own. The
information on the belt supplied with this machine is in Section 10 of this manual.
8.3.5. i ** : The nip roller should initially be set at 150 psi at the
pressure valve on the hydraulic unit. Optimum settings for the nip roller must be
determined with the belt press in operation. The nip roller pressure will be a function of
the sludge type, and belt speed. The optimum setting will occur at the point where
additional pressure by the nip roller removes excess water, without squeezing sludge out
the sides, or embedding the sludge excessively into the belts.

8.4. $press Calculations: To evaluate the Winklepress® performance, it is important
to understand the basic calculations involved.
8.4.1. Loading. Rate:
Rate = gpm Sludge X (Percen, Feed Solids/100) X 8.34 X 60
Example: Determine pounds per hour of sludge if percent feed solids is 2.0 and sludge is
being pumped at 100 gpm.
Divide percent feed solids by 100 to convert percent to decimal
(2/100) = 0.02
8.34 = Approximate weight of one gallon sludge
60 = Minutes per hour
100 gpm X (0.02) X 8.34 X 60 = 1000.8 Pounds per Hour
I Percent Concentration = (Gallons Polymer/Gallons Water) X 100
Example: Determine percent polymer concentration using 2.5 gallons polymer and 1000
gallons of water
2.5/1000 = 0.0025 Multiply by 100 to convert to percentage
0.0025 x 100 = .25%
b. D-a P m
Percent Concentration = [Pounds Polymer/(Gallons Water X 8.34)] X 100
Example: Determine polymer concentration using 10 pounds dry polymer and 1000 gallons
water.
Convert gallons to pounds - 1 gallon = 8.34 pounds
1000 X 8.34 = 8340 pounds
10/8340 = 0.0019
To convert to percent, multiply be 100
0.0019 X 100 = .119 or .12% (rounded)

8.4.3. Polymer Usage:
Pounds Polymer per Ton of Feed Solids = [gpm Polymer X 8.34 X 60 X
(Polymer Concentration/ 100)]/Loading Rate in tons per hour
Example: Determine polymer usage if 5 gpm of 0.25 percent polymer is used with a
loading rate of 1000 pounds per hour.
Convert percent polymer to decimal by dividing by 100
0.25/100 = 0.0025
Convert feed rate to tons by dividing by 2000
1000/2000 = 0.50
8.34 = Approximate weight of one gallon sludge
60 = Minutes per hour
(5 x 8.34 x 60 x .0025)/0.50 = 12.50 pounds per ton
8.4.4. Capture Rate.
Percent Capture =[(Feed Solids - Effluent Solids)/Feed Solids] X 100
Example: Determine percent capture if feed solids is 3 percent and effluent solids is 250
milligrams per liter
Convert 250 mg/L to percent by dividing by 10,000
250/10,000 = 0.025 Percent
[(3.0 - .025)/3] x 100
[2.975/3] x 100
.9916 x 100
99.16 Percent Capture
8.4.5. Throe hnut:
Throughput = Loading Rate X Percent Capture/100
Example: Determine throughput if sludge is fed at 100 gpm having a 2.0 % concentration
and 99.16 % capture rate.
Using the above calculations, loading rate is 1000 pounds per hour.
1000 X 99.16/100 = 991.6 pounds per hour

8.5. Prgcess Start
8.5.L Start wash water.
8.5.2. Start hydraulic power unit and set pressure at 350 psig.
8.5.3. Ensure hydraulic control valve is in tension position and belt is tensioned.
CAUTION: Starting the drive unit without tension on the belts could damage the belts.
8.5.4. Start belt drive and run for approximately two minutes to pre -wet the belt.
The belt speed should be approximately fifty percent of its maximum.
8.5.5. Start sludge and polymer pumps so that both reach the in line mixer
simultaneously. The mixer should be half closed to start.
8.5.6. Adjust feed chute so that sludge is evenly distributed onto the belt.
Note: Improper sludge distribution will cause reduced dewatering capacity and uneven
wear on the belt Dress.
8.5.7. Adjust side sludge restrainers until most solids are retained inside the
restrainers. Water seeping under the seals is common and will not hurt the dewatering
process.
8.6. r ce s d' S men s: Because the dewatering process is dependent on numerous
variables, it is important to understand how changes in the process will affect the end
result. All of the process variables have an optimum point depending on the other
variables. Because of this, Ashbrook recommends adjusting the process slowly by
changing one variable at a time and logging the results. A suggested order for adjusting
the proccess is:
8.6.1. Adjust sludge feed rate to achieve the throughput desired.
8.6.2. Adjust polymer flow for proper flocculation.
8.6.3. Adjust belt speed.
8.6.4. Adjust vertical wedge plate.
8.6.5. Fine tune the performance by adjusting the belt tension, mixer, chicanes, etc.
Note: As changes occur in the sludge or polymer, adjustments will be required in the
dewatering process.
8•7• House Keeiand Clean : Refer to the detailed information in the Daily
Operation Section of this manual for the house keeping and clean up required prior to
shutting down the machine.
3
,-
8.8 Pr4_cess . Diagnosti h art
8.9 EMMA SamRlle Log Form

PROCESS DIAGNOSTIC
Insufficient Polymer
Sludge squeezing from the belts
Large weak flocs
Poor gravity dewatering
Gravity section overflows
Poor capture rates
Wet cake
Insufficient Mixing
Large clumpy flocs
Filtrate in sludge inlet is cloudy
High filtrate solids
Low cake dryness
Cake sticks to belts
Excessive Polymer
Foaming at sludge inlet
Sludge feels "slimy"
Filtrate is foamy and slimy
Puddling in the gravity section
High polymer bills
Cake sticks on belts at discharge
Excessive Mixin
Sheared flocs
Poor gravity drainage
High filtrate solids
Sludge squeezes from belts

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ASHBROOK WINKLEPRESS® : • . IF I
MOM IM
0 DAILY OPERATION:
9.1. Gener : These procedures cover the routine operation of the Winklepress and
should be used as a model for a plant's customized procedures.
9.2. Pre- ration: This covers the steps which should be followed prior to starting
any of the belt press functions. These steps help ensure the safety of the operators as well
as the equipment.
9.2.1. Pre-SMIn c'
a. Verify no foreign objects are on belts or in an area that will interfere
with the belt press operation.
b. Ensure chicanes are positioned on belt.
c. Verify tensioning control valve is in the tension position and that the
belts are ready for tensioning.
d. Ensure all feed pumps are ready for operation and all valves are open.
e. Verify panel and machine have not been locked -out due to a prior alarm
or maintenance condition.
operation. f. Inspect hydraulic power unit and verify the oil level is adequate for
9.2.2. Sta : the start up sequence detailed is for a completely manual start up.
Depending on the installation, the electrical controls may have the capacity to completely
automate the start up. However, it is important to know the manual start up process to
evaluate the effectiveness of the control system.
a. Start belt wash system.
tension. b. Start hydraulic system and allow two minutes for belts to completely
c. Start belt drive system and allow the belt to be completely pre wetted
prior to adding sludge.
d. Start sludge and polymer feed pumps.
9.3. ration: The routine practice of inspecting the belt press during the operation
phase will help keep it running with minimal down time. The inspection instructions are
divided into mechanical and process checklists for the aid of the operators and mechanics.
9.3.1. Mechanical In tin:
a. Ensure feed assembly is evenly loading the belts.
b. Ensure chicanes are turning sludge mass and inspect them for wear.
Replace chicanes as required.
c. Ensure edge restrainer seals are contacting the belts and seals are not
worn. Replace or adjust seals as required.
d. Ensure doctor blades are functioning correctly. Inspect blades for wear
and replace as required.
e. Inspect gravity drainage grid for wear. Replace wear bars before belt
contacts metal support grid.

f. Ensure belt wash system is completely cleaning belts. Look for
streaking or striping on the belts. If present, rotate the wash water handwheel fully counter
clockwise and then fully clockwise to clean the spray nozzles.
g. inspect wash box seals for wear. Replace as required.
h. Inspect dewatering belts for wear. Repair holes per maintenance
instructions. Repair or replace broken belt seam wires.
i. Ensure steering sensing paddle is in contact with the belt and correcting
belt steering as required.
j. Ensure there are no leaks from any of the systems.
k. Inspect roller coatings for wear and ensure flingers are in place.
L Ensure all electrical controls are functional.
a. Adjust sludge feed rate for process throughput requirements.
b. Adjust polymer feed rate until flocculation is correct.
c. Adjust belt speed for above conditions.
d. Ensure mixing energy is in the correct range.
e. Adjust belt tension and nip roller tension"`f available as required for
optimum dewatering.
9.4. NorimW Shut -Down: The key to minimal down time, reduced
maintenance cost, and a void of warranty, is good housekeeping and preventive
maintenance. If the belt press is inspected and maintained daily, it can be counted on for
years of service. The following guideline should be used for daily machine shut down and
cleaning:
9.4.1. Shut down the sludge and polymer feed systems.
9.4.2. Allow the belt wash stations to run for a minimum 45 minutes without any
sludge or polymer feeding onto the belt press. During this time period:
a. Lift the chicanes off the belt.
b. Wash down the Winklepress from top to bottom using a garden hose.
assembly. c. Rotate the scraper blades away from the belt and hose down the scraper
d. Wash out the drain pans.
e. When the machine is completely washed down and free from sludge,
replace the chicanes and scrapers in their operating position.
f. Clean the wash water spray tubes by rotating the wash water hand
wheels completely in the counter clockwise direction and then completely in the clockwise
direction.
9.4.3. Shut down the drive unit.
9.4.4. Shut down the belt wash water system..
9.4.5. Move the tension control valve on the Winklepress to the retract position.
Allow the belt to completely detension.
9.4.6. Shut down the hydraulic power unit.
9.4.7. Move the tension valve to the tension position.
9•$• h : the machine could be stopped without going through the
normal shut down sequence due to a mechanical failure or other emergency. While the
machine will not be damaged due to this type of shutdown, the life of components could be
shortened by not cleaning the belt press. If the machine is shut down because of an
emergency, the following steps should be taken:

CAUTION. Starting the belt drive at full tension with cake between the belts places
unnecessary stress on the belts, belt drive motor, and rollers. This could lead to
premature mechanical failure.
9.5.1. Identify the problem and estimate the down time.
9.5.2. If the machine will be down for more than one shift then:
a. Wash the machine down to prevent sludge from drying on the belts.
The area where both belts are in contact with the sludge (pressure section) should be given
extra effort.
b. If possible, relax the belt tension.
c. Correct the emergency condition.
d. Start hydraulic power unit and reduce hydraulic pressure to 250 psig by
adjusting the pressure control valve on the hydraulic power unit.
e. Place the tension valve in the tension position and allow the belts to
tension.
CAUTION. Starting the belt drive at full tension with cake between the belts places
unnecessary stress on the belts, belt drive motor, and rollers. This could lead to
premature mechanical failure.
f. Start wash water and allow belts to pre -wet.
g. Start belt drive. If belts are not clean, allow the machine to run for 45
minutes to complete a belt wash down cycle.
h. Increase belt tension to normal limits (350 psig).
i. Start sludge and polymer feed systems and begin dewatering.
9.5.3. If possible, detension the belts by placing the control valve in the retract
position.
9.5.4. Correct the emergency condition.
9.5.5. Start the hydraulic power unit and reduce the pressure to 250 psig.
9.5.6. Place the hydraulic control valve in the tension position and allow the belts to
tension.
9.5.7. Start the belt wash system and allow the belts to pre -wet.
9.5.8. Start the belt drive.
9.5.9. Increase hydraulic pressure to normal limits (350 psig).
9.5.10. Start sludge and polymer. feed systems.
9.5.11. Continue dewatering process as normal.

ASHBRQQK WINKLEPRESSO
-..
10.0 MAINTENANCE
10.1. GENERAL: Maintenance instructions will be divided into the same
functional groups as indicated in the General Mechanical Description of this manual.
Drawings, cut sheets or schematics, if applicable, will be indicated in the appropriate
section. The intervals indicated are based on a normal work or operating schedule of forty
hours per week.
10.2. DAjLY MAINTENANCE :
10.2.1. Clean belts by running belt drive and wash system without sludge
or polymer for a minimum period of 45 minutes.
10.2.2. Clean spray nozzles on wash boxes.
10.2.3. Check fluid level in hydraulic unit. Fill as required.
10.2.4. Inspect alarm sensors.
10.2.5. Check emergency trip cord by manually tripping circuit and
resetting.
10.2.6. Check emergency stop button operation.
10.3. $TEE LY MAINTENANCE ITEMS:
10.3.1. Inspect wear items specifically chicanes, scraper blades, gravity
drainage grid, dewatering belts, rubber seals on the sludge restrainers and
the wash stations. Replace as required.
10.3.2. Inspect frame and roller coatings for wear.
10.3.3 Inspect racks and pinions for cleanliness/wear. Clean as required.
10.4.MONTHLY M I A E ITEMS.
10.4.1. Verify daily and weekly items have been completed
10.4.2. Clean belts with a soap/bleach mixture.
10.5.1. Verify monthly items have been completed.
10.5.2. Lubricate bearings.
10.5.3. Replace hydraulic filters.
10.5.4. Lubricate primary drive gears.

10.7 ROLLERS:
10.7.1 Inspection Items:
a. Inspect roller coating for damages.
b. Minor chips and scratches can be repaired using a touch
up kit.
c. Contact Ashbrook for re -coating worn out coatings.
10.7.2 Drawings:
SK001606 - Roller Assembly
WP97-10 Rev. 2
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10.8 BEARINGS:
10.8.1 Bearing Cut Sheets: See attached
10.8.2 Pillowblock Dimensional Data: See attached
a. Spherical Roller Bearing Dimensional Data
b. Cylindrical Roller Bearing Dimensional Data
10.8.2Inspection Items:
a. Ensure grease is visible on bearing/shaft seal.
b. Check bolts.
c. Ensure roller flinger is in place.
10.8.3 Lubrication Procedures:
Note: Lubricate bearings every six months with 3 to 5 ounces of grease per
bearing. Use only the lubricants contained in the lubrication cross reference in this
manual. Failure to lubricate the bearings will invalidate the bearing warranty.
a. Attach grease gun to button grease fitting.
b. Inject three to five ounces of grease. Grease should be seen.
c. Disconnect grease gun and continue with remaining bearings.
d. Repeat until all bearings are lubricated.
1
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WP97-10 Rev. 2 5

ASHBROOK
LEADERS
i1V
LIQCiII)/SOLID
SEPARATION
Searing Retrofit
The Bearing Retrofit is one in a .
series of PerforriUnce.Improae-
meat products by Ashbrook
Corporation. These products are
designed to enhance the capability
of a belt filter press, by either
increasing throughput, increasing
dry solids content, or reducing
operation and maintenance costs.
This Bearing Retrofit can be
installed an any:
• Klampress® belt filter press
(manufactured before 1989)
• Wwklepress® belt filter press
(manufactured before 1989)
• Aquabelt® gravity belt thickener
(manufactured before 1990)
Because this upgraded bearing
has a 6 month lubrication cycle*
(versus 100 days for the original
bearing) operation and mainte-
nance costs are dramatically
reduced. The Bearing retrofit
maintains superior performance in
dirty, dusty, or wet environments. It
is ideal for both municipal and
industrial installatLons.
TG
This retrofit is specifically designed
to provide superior sealing, thus
Protecting the lubricant and bear-
ing from external contamination
which can cause wear. The lubnca-
lion cycle is .
increased
because this
triple tech / triple
labyrinth seal
retains the
lubricant within
the housing
better than
traditional felt
seals.
The Bearing
Retrofit is a
certified Ashbrook part, It meets the
high quality standard established by
Ashbrook Corporation.
Each Bearing Retrofit consists of the
following components:
• nylon coated, cast iron, pillow
block housing
• spherical roller bearing with
metallic retainer cage
rubber triple tech / triple labyrinth
seal
• easy -access grease fitting
This Bearing Retrofit is designed to
resist high pressure wash -downs,
grit and other abrasives, while
operating over a wide range of
temperatures.
hivausimis • c u : ►
The Bearing Retrofit requires
greasing only every 6 months*. A
grease fitting is located on all
bearing housings, malting greasing
easy and convenient. This reduction
in greasing intervals results in direct
maintenance cost savings.
Because of the superior design
of the Bearing Retrofit, roller dam-
age resulting from poorly main-
tained bearings is reduced.
N
The Bearing Retrofit can be installed
by skilled Ashbrook technicians who
are factory trained and certified or
by plant maintenance personnel.
The Bearing Retrofit is available in the
following shaft sizes:
• 2 shs"
• 2 s/is"
• 60 min
• 90 rnrrs
• 100 min
It is also available with a 2 or 4 bolt
hole pattern.
For assistance in choosing the
correct size, a detailed proposal, or
for more information on this product
or other Performance Improvement
Products, please contact the Spare
Partslltefrafit Departm6nt at the
Ashbrook Houston office.
+ *provided recommended grease is used
lZMERS INi
Li4i7tD/SOLdd SEPBRATlON
Ashbrook Corporation • 11800 East Hardy • Houston, Texas 77093-1098
Phone: [phone] • Pax: 281-449-1324 • Toll Free: 1-8DO-362-9041 1®
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WINKLEPRESS
IMPROVED TRIPLE- TECT SEAL -DESIGN
FF"TURES:
)SING SEAL IS PATENTABLE
i`NIPLE-TECT DESIGN
COMBINATION NON-METAL LABYRINTH
SEAL, DYNAMIC' FACE RUBBING LIP
SEAL, AND STATIC SHAFT -SEAL
DYNAMIC LIP SEALS AGAINST
STAINLESS STEEL SEAL RING AND
WILL NOT DAMAGE THE SHAFT
BENEFITS:
rmow
LrAnum 1N
uoulD/som sEPAMMON
Ashbrook Corporation
P.O. Sax 16327
Houston, Texas 77222
0 ALLOWS FOR GREASE PURGING
WITHOUT EXCESSIVE PRESSURE
BUILD UP IN HOUSING
ALLOWS FOR BEARING
MISALIGNMENT AND EXPANSION
SEALS STATICALLY ALONG SHAFT -
SEAL ROTATES WITH SHAFT
SEAL ASSEMBLY CONTAINS OZONE SHAFTCONTACT WILL NOT DAMAGE
RESISTANT STATIC.AND DYNAMIC
SEALS WITH WEATHER RESISTANT NO CORROSION OR TEAR ON SHAFT
NYLON LABYRINTH CARRIER/FLINGER 0 UNDER SEAL SURFACE '
FACE CONTACT SEAL IS REPLACEABLE PROVIDES SUPERIOR SEALING
WITHOUT REMOVING BEARING FROM 0 ACTION IN WET ENVIRONMENTS
SHAFT OR•HOUSING FROM FRAME
HOUSING SEAL RING PROVIDES
CONTINUOUS SEALING SURFACE
0 AND PREVENTS POTENTIAL
SEAL LIP DAMAGE DURING
INSTALLATION
SEAL ASSEMBLY HAS BEEN LIFE
• TESTED AND MET ALL DESIGN
CRITERIA

1 0

10.9. STEERING ASSEMiLy:
10.9.1. Damingg;
a. Steering Assembly
b. Hydraulic Steering Cylinder Data
10.9.2. Inspection Iwms:
a. Ensure sensing paddles are moving with belts.
b. Ensure both steering cylinders are responding to sensing paddles.
c. Ensure belts are tracking in approximately the center of the belt
press.
d. Ensure belt misalignment Iimit switches are functioning.
a. Shut down belt press and lock out controls.
b. Unbolt wear strip from paddle.
c. Position new wear strip on paddle and replace bolts.

Hydraulic
Winklepress
Cylinders
Size 1, 2 & 3
Tensioning Cylinders
Part Number:
027452
Mounting Style:
Flange Mounted
Service:
750 psig
Cushion:
Non -Cushion
Bore Size:
2.5"
Stroke:
12"
Rod Diameter:
1.75"
Steering Cylinders
Part Number:
026520
Mounting Style:
Double Rod End Tapered
Service:
750 psig
Cushion:
Non -Cushion
Bore Size:
4"
Stroke:
4"
Rod Diameter:
1.75"
ASHBROOK CORPORATION

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10.10. TENSIOriTNG AMEMBLy:
10.10.1.E wines;
a. Lower Belt Tensioning Group Assembly
b. Upper Belt Tensioning Group Assembly
c. Hydraulic Tensioning Cylinder Data
10.10.2. LnnSpection, Items:
a. Inspect tension cylinders for leaks.
b. Inspect racks and pinions for cleanliness/wear.
10.10.3. Lubrication Ins i n
a. Connect grease gun to button bead grease fitting.
b. Inject three to five ounces of grease.
c. Continue until all fittings are greased (2 per cylinder).
10.10.4. Tension Valve Rea menti
a. Shut down belt press and lock out controls.
b. Disconnect hydraulic lines from valve.
c. Unbolt valve from frame.
d. Bolt new valve to frame.
e. Replace hydraulic lines.
f. Check for proper belt tensioning operation before starting belt
drive.

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Hydraulic
Winklepress
Cylinders
Size I, 2 & 3
Tensioning Cylinders
Part Number:
027452
Mounting Style:
Flange Mounted
Service:
750 psig
Cushion:
Non -Cushion
Bore Size:
2.5"
Stroke:
12"
Rod Diameter:
1.75"
Steering Cylinders
Part Number:
026520
Mounting Style:
Double Rod End Tapered
Service:
750 psig
Cushion:
Non -Cushion
Bore Size:
4"
Stroke:
4"
Rod Diameter:
1.75"
ASHBROOK CORPORATION

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10.11 HYDRAULIC POWER UNIT:.
have parts that are maintainable in the
required, please call Ashbrook.
10.11.1 Drawings:
The hydraulic pump and motor do not
field. If maintenance on these items is
a. Hydraulic Schematic: SK001303
b. Hydraulic Pump/Motor Assembly Drawing: 029838
c. Manifold Assembly Drawing: 029868
d. Hydraulic Reservoir Drawing: SK001405
e. Hydraulic Filter Drawing: 029836
f. Pressure Switch Data Sheet
g. Pressure Gauge Data Sheet
h. Motor Data Sheet
10.11.2 Filter R lacement:
Note: Change oil and clean filter screen semi annually (every six months).
Retract the tension cylinders to return most of the oil to the reservoir. This will
help purge more of the old oil and prevent over filling the reservoir.
a. Unscrew the bowl from filter body; catch the oil in a bucket.
b. Remove and wash the suction screen. Be careful not to
damage the screen.
c. Reinstall the screen in the filter bowl. Do not operate without a
filter screen installed.
d. Screw the filter bowl back onto the filter body.
e. Refill the hydraulic reservoir to the high level mark.
10.11.3 Hydraulic Fluid:
Note: Change hydraulic fluid after 500 hours or anytime fluid appears discolored
or cloudy. The hydraulic oil can absorb moisture from the atmosphere.
a. Check oil level when tension cylinders are retracted. If fluid is
too low, add sufficient fluid to restore proper level. Find and
repair any leaks, which caused fluid level to decrease.
b. Inspect the level of the oil and its color. If fluid is discolored,
drain and replace.
c: Hydraulic fluid is drained by removing the filter bowl and
catching the oil in a bucket.
d. Properly dispose of any waste oil.
e. Start hydraulic unit and allow belts to tension.
f. Retract the cylinders and check the level of the hydraulic oil in
the reservoir and add oil as required.

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ACCESSORIES
1 M
PRESSURE GAUGES
Uti Iity Gauges:
Steel Case, Non-Filled,118" & 114" NPT Ports, Vacuum to 600 PSI
AIR SERVICE
CB- Center Back Ports
LB- Lower Back Paris
CB- Center Back Ports
BM- Bottom Ports
il- Mounting clamp
P- Panel Mounting
GENERAL
HYDRAULIC
SERVICE
Above utility mounting
Styles also available this series.
Crimped bezel standard, TWst on
bezel available on wall mount and
basic bottom port gauges only
(shown to the right).
OEM_ Gauges: Stainless Steel Case, Glycerin-Filled,1/8" 1/41, & 112" NPT Ports,
Vacuum to 15,000 PSI
Crimped Case- Standard
GAUGE PART NUMBERING SYSTEM:
NYV 2� - 2
TB-1ialst on Bezel W Wall Mounting
(optional) T6- Twist an Bezel
B - Q - Qpt o Co s - (Oml# it None)
-30Vac 160
1 800 6k
1.5
2. 1/8" MP N- None BM- Bottom
15 200
1 k 10k
2
4- 1/4" MP P- Panel CH- Center/ Back
30 300
1.5k 15k
2.5
8- 1/2" MP U- U-Clamp 1.8- Lower/ Back
60 400
2k 20k
4
417- 1/e" MP W- Wall
100 500
3k 25k
6
4MS- 4MS
600
4k 30k
4A- 9/18-18 Aminco
5k 35k
6A- 3/4.16 Aminco
Available Dry
or Filled
Available Fllleci
Example: : 0-2000 psig, 2,5" Dia., 1/4"Male NPT, U- Clamp
Mounting, Center Back Ports, OEM Series- Glycerin Filled
Case
Internals
Fili Fluid
Options (Listed Alphabetically)
B- Brass
B- Brass
D- Dry
A- Adapter MP- Max Press.
C- 304SS
C- 304SS
F- Filiable
Fling 4-1/2" Pointer
D- 316SS
D- 316SS
G- Glyceryn
B- Bar/ Psi P. Plastic Lens
P- Polyamid
M- Monel
S- Sil€con
C- Calibrated R- Red Stationary
S- Steel
S- Steel
G- Glass Lens Pointers
K kPa/ Psi RS- Restrictor
K2- kg/sq-cm Screw
MD- Mirror Dial SB- Solid Front/
w/ Knife Edge Blow -Out Back
Pointer T High Temp
MM- Min/ Max Service
Pointers Z- Special/ Write
Out
O- Hyd. Service; Glyc,
Filled, 304SS Case,
Brass Internals
U- Air Service; Dry, Non-
Filled,Steel Case, Brass
Internals
M- Mfg Code
This code must be in
place to continue options

PI2ESSur-9WI7�µ
CLo W- �f �D12flIALt C�
'lw
P/ • J✓ BARKSDALE, INC. • 3211 Fruitland Avenue, P.O. Box 58843 • Los Angeles, CA 90058 • [phone]
D z-q " —�Z OPERATING CHARACTERISTICS • ORDERING DATA
General Description
The 96200 series switch utilizes a seated piston sensor. The 96210
and 96220 series switches use a diaphragm piston sensor.
Each switch is factory set to meet your specific application
requirements. The dfllerenlial is Bxed and varies with pressure selling,
Electrical Connections include free leads as standard with oplionaf
spade terminals. DIN type connector or 112' NPT conduit connector
(mate at female).
These factory set pressure switches are environmentally sealed and
are resistant to shock and vibration. Designed to deliver millions of
maintenance Iree. cycles, the sealed piston and diaphragm piston
designs are ideally suited lot harsh environments.
RESSURE VACUUMolor
Pin
Color Pinlue
2
Red 3urple
1
M
Purple 1ed
3
Blue 2Nal
used
Nat used
All models Incorporate Underwrilers' Laboralories,
Inc. 6sled and CSA approved single pole double
throw snap -action switches.
LFKELFADS I
MM NO
rs xrr MUE
1'REs51lI�r0Rr
rk
STANDARD MODEL
FACTORY SET PRESSURE SWITCH —All values given in P.S.i, (Gauge)
Range
Pressure Setting Range
Decreasing Increasing
Min. Max. Min. Max.
I Approx.
Actuation
Value
(Differential)
Proof
Pressure
Catalog
Number
30' Hg (vac)
I'Hg
WHO
6' Hg
30' Hg
1-6' Hg
30 psi
96220-Bal *
15
2.5
12.8
3
15
.5-2.2
1000
96210-Bat*
35
5
31
6
35
1.0-4.0
1000
96210-BB2*
50
8.5
44
10
5o
1.5 6.0
1000
96210-BB3
125
22.5
112
25
125
2.5-13
1000
96210-884
250
73.0
220
80
250
10-30
1000
96210-885
500
Ila
440
130
500
20-60
1000
96210-BB6
600
ISO
450
250
6Q0
60-150
7000
96240 B81
1100
350
1450
430
1700
70-250
7000
96200-SB2
4400
1450
3900
1650
440D
200 500
7000
96200-883
7500
365Q
1 6700 1
4000 1
7500
350-800
12000
96200.BB4
Approximate Shipping Weight: 02 lbs.
Detail Data
Electrical Connection
Free leads approximately 12' long.
Pressure Connection
1/4' NPT mate.
Temperature Range
96200 series - —40' to 1657.
96210 series - —20' to 165°F.
(*0'F Min. as noted)
96220 series — 0' to 165°F.
Welled Materials
96200 series 96210 & 96220 series
Body — Brass Body — Brass
Seals — Buna N o'ring Diaphragm— Buna N
Piston —Stainless steel
Housing
Open type plastic housing.
Approvals/Lislings
UL and CSA recognized.
Optional Modifications
Electrical
See below.
Wetted Material
Body: Stainless steel. To specify, add sullix -SS to catalog number,
Diaphragm/Seal
Other compounds available. Consult factory.
Process Connection
7/16-20 SAE type male straight threads with wring seal, add suffix -P1.
1/4' BSP male straight threads with wring seal, add suffix -P3.
Ordering instructions
To ensure correct switch Is furnished, always specify full catalog number
(including required modifications), set point [increasing or decreasing) and
service. Example: 96210-BB2-SS-T2 set at 15 psi increasing. Service, Dry
Nilrogen.
e ae
425
Mere With
Q
hannectur far Wllh
12' Frog Leads
712. NPT Mile. p
Specify Sight-T4 CIP
Female CoadNn
CDeseetor with
12' Free Lands
112'nP7 Female.
Specify Sunix 45
Spode Terrnhral
Connector DIa Connector
1r4' Male Oukk Out 43650 Type.
Connect Ternrgla. Specity Sidli -T2
speedy Sulfix JI
19

�TECO
INDUCTION MOTORS
MAXwEIT11 Premium Efficiency
Severe Duty Motors

Performance Data MAX-E1TM Premium Efficiency, Type AEHE
Totally -Enclosed Fan -Cooled, 3/60/230-460V (usable on 208V); 575V
NSMA Design 8 or Design C, Class F Insulation, 400C ambient, Continuous Duty,1.15 S.F.
:..
. III�I.
•
tI1tV1EN�'��
,
` ifs
D01N ;r
!t¢E"
P�
l
.
T
��
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f4L
0 75
1150
143T
3.4
82.5
80.0
61.0
1.4
175
12.5
275
0.105
1
1745
143T
3A
86.5
84.1
77.0
1.4
310
15.0
410
0.103
N
53
1150
145T
4.6
85.5
63.4
59.5
1.7
260
15.0
32p
Q.13g
N
59
1.5
3480
1730
143T
14ST
2.3
4.6
86.5
65.5
84.0
85.0
84A
81.0
2.0
340
2Q.O
350
0.052
M
53
1180
162T
6.7
86.5
OSA
67.0
2.1
2.4
300
210
20.0
20.0
360
350
0.118
0.317
M
M
57
90
2
3480
1730
145T
145T
3.0
86.5
85.5
a6.5
2.6
350
25.0
390
0.054
L
57
1165
184T
GA
9.0
86.5
87.5
85.3
06.5
BOA
69.0 13.2
2.8
320
200
25.0
Z5.0
360
310
0.136
0.392
L
L
62
101
3520
182T
4.5 1
87.5
85.5
91.5
3.6
280
32.0
340
0.190
K
90
3
1750
82
1T
8.9
88.5
87.5
85.0
3.8
240
32.0
350
0.349
K
95
1165
213T
13.5 1
88.5
87.0
78.0
4.2
220
32.0
300
0.7.44
K
139
3520
184T
7.5
89.5
87.7
93.5
5.7
290
46.0
320
0.272
J
106
5
1750
1165
184T
215T
15.0
89.5
88.1
86.5
6.2
250
46.0
330
0.500
J
114
22.7
89.5
87.5
80.5
6.7
200
140.0
280
1.058
J
165
3525
1755
213T
11'2
81.0
89.8
90.0
8.7
2D0
63.5
275
0.449
H
156
7.5
213T
22.4
91.7
90.3.
86.5
9.0
270
63.5
30D
0.790
H
167
1170
254T.
33.7
91.7
90.4
81.5
9.5
240
63.5
270
2.158
H
267
3525
215T
15.0
91.7.
1 90.2 1
90.5 t
11.5
290
I ai_O I
Pan f
n a7a 1
u
ern
10
1 T=
215T
30.0
91.7
90.4
1 88.0
11.8
260
81.0
290
1.024
H
189
1170
256T
44.9
91.7
90.4
81.5
12.7
240
81.0
260
2.657
H
295
3540
254T
22.3
91.7
91.3
92.5
16.7
210
11a.0
270
1.088
G
262
75
1760
254T
44.8
1
82.4
91.a
69.0
17.3
245
116.0
270
2.179
G
288
1175
284T
67.0
91.7
90.9
834
18.5
240
116.0
240
6.255
G
414
20
3540
1765
258T
256T
29.8
59.5
92.4
93.0
21.2
92.5
82.$
2 00
145.0
2g0
1.407
G
315
1175
286t
1 89.7
92.4
82A
91.0
89.5
83.5
22.8
24.5
230
200
145.0
145.0
260
230
2.741
7.961
G
G
332
473
3545
284TS
37.0
93.0
92.1
92.0
1 27.8
175
182.5
250
2595
G
418
25
f5
11
324T284T
112.0
93.0
92.4
82.0
31.0
200
1 SZ5
220
10,587
G
623 '
3545
28M
44.4
93.0
92.2
91.5
33.6
175
2-17.5
240
2.930
G
455
30
1765
286T
89.0
93.6
92.7
08.0
34.5
230
217.5
250
5.044
G
475
1175
364T
134.0
93.6
92.5
83.0
KS
210
217,5
230
12.372
G
697
3540
328T8
59.0
94.1
93.1
91.5
44.0
150
290.0
220
3.590
G
618
40
1770
326T
119.0
94.1
93.2
89.0
45.3
220
290.0
240
8,624
G
664
1175
365T
178.0
94.1
93.1
85.5
47.0
2DO
290.0
220
17.938
G
898
3540
326T5 1
74.0
94.1
93.0
91.5
55.0
150
362.5
240
4.4aa
G
893
50
1770
328T
148.0
940
93.2
BB.O
57.0
220
3615
240
10.124
G
724
1175
386T
223.0
94.1
93.1
O&S
58.5
200
362.5
215
21.386
G
911
60
3535
1775
364TS
364T
89
94.1
93.0
92.6
65.5
140
435.0
220
7.380
G
' 81a .
1176
404T
178
95.0
94.1
86.0
69.5
200
435.0
230
11.739
G
858
267
94.1
83.6
88.5
sax
210
435.0
230
30.289
G
1164
3640
365T5
111
94.1
93.5
93.5
80.5
135
642.5
230
8.721
G
am
75
1177
40WST
222
01
54zs
220
334
94.
93.6
89.0
84.5
2 0
545.0
250
36.239
G
440
130
100
3550
1775
40M
405T
147
me
95.0
95.0
94.1
94.5
90.0
89.0
110.5
111.5
140
200
725.0
725.0
250
250
M774
G
G
1320
1180
444T
445
95.0
94.1
84.5
117
200
725.0
220
28,037
58.400
G
1430
1675
3564
444TS
184
95.0
94.1
89.5
138
108
910'0
220
18.600
G
1530
125
1778
444T
368
95,4
94-5 1
87.0
140
200
910.0
220
44.300
G
1850
1180
445T
Z55 1
95.0
84.1
a5.7 1
144
200
910.0
220
72.800
G
1910..
15D
3558
1180
44M
445T
220
441
95.0
96.4
94.1
94.5
90.2
88.5
164
107
1085.0
210
21.800
G
logo
1182
447TZ
ON
95.0
94.1
86.5
165
171
200
200
1085.0
1085.0
210
210
52.200
110.000
G
G
1820
2315
200
3580
1765
447TS
447TZ
294
587
95.4
95.8
94.5
91.3
215
103
1450.0
210
34,300
G
2220
1185
44M
885
95.4
95.0
94.5 '
88.6
84.7
220
232
20O
200
1450.0
1450.0
210
210
16200
133.000
G
G
.2380
2685
250
35M
1786
4497S
449TZ
366
734
95.4
95.a
94.5
91.3
209
103
1a25.0
'210
44,400
G
187
449TZ
95.0
89.2
274
2D0
1825.0
210
90-300
G
:r:20:]
1105
95A
94.5
85.2
288
122
la25.0
210
158.000
G
Note:
i. The above are typical values based on test.
2. Actual load and full voltage starting: According to ANSWEEE standard 112-1978 method B.
3. Minimum guaranteed efl'rctency values can be certified with actual tests.
4. 13reakdown and locked rotor torque are shown as NSMA minimum values.
5. 150 HP and above are 460V only.
6. Data subject to change without notice.

• Dimensions Totally -Enclosed Fan -Cooled Horizontal Foot -Mounted, Type AEHE
e
Figure 1
FRAME
SIZE
143T
145T
•182T
164T
213T
215T
254T
256T
284T
284T5
286T
286TS
324T
324TS
326T
32M
365T
365TS
404T
405T
4 4TS
446M
447TS
449TZ
449TS
FIGURE
t
2
3
4
11 E . 2F
2.75 4.00
2.75 5.00
3.75 4,50
3.75 ass
4.25 6.50
4 25 7.00.
5.00 8,25
5.00 10.00
5.80 9.50
5.50 9.50
5.50 11.00
5.50 11.00
6.25 10.50
6.25 10.50
6.25 12.00
6.25 12.00
7,00 11.21
7.00 11.25
7.00 12.25
7.00 1 12.25
&00 1Z25
8.00 13.75
&00 13.75
9.00 14.50
9.00 14M
9.00 10.50
9.00 9.00 1'am20.00
9.00 20,00
9.00 2&00
9.00 26.00
711
T'
143T
7.87
-
145T
7.87
-
182T
9.37
1 90
184T
9.37
1.30
213T
10.75
1.65
215T
10.75
1.65
254T
13.15
ZOO
256T
13.15
2.00
284T
15 Os
2.00
284T5
15.05
2.00
286T
15.05
2.00
286TS
ISM
2.00
324T
i6.55
2.35
324TS
16.55
2.35
326T
16.55
2.35
326T5
16.55
2.35
MT
18.05
2.80
364T3
11.05
2.80
365T
18.05
2.80
365TS
18.05
2.80
404T
20.60
250
405T
20.60
2.50
405TS
20.80
7-50
444T
23 00
3.25
444T5
23.00
3.25
445T
2 M
3.25
445T5
I
23.00
3.25
447TZ
25.3s
Ms
4.10
447TS
4.10
449TZ
25.35
4.10
44STS
25.35
4.10
4
• e �r�Lj:.�r
L-i�.L; •Lys'
� 'lil'6lN
Figure 2
111 I Ulu
A
B
H
' BA
34
2,25
6.70
5.10
34
2.25
8.70
5.90
Al
2.75
8.80
5•.90
A 1
2.75
8,80
6.90
.41
3.50
"9.85
6.90
.41
3.50
9.85
8.35
.53
4.25
11.80
9.86
.53
4.25
11.80
f 1.80
.53
4,75
14.00
11.70
.53
4.75
14.00
11.70
.53
4.75
14.00
13,20
.53
4.75
14.00
13.20
66
5.25
15.57
12.80
As
5.25
15.75
12.80
.56
5.25
15,75
14.35
.66
5.25
15.75
1425
6fi
5,88
17.70
14,75
6s
5.88
17.70
14.75
$B
5.88
17.70
14.75
.66
5.88
17.70
14,75
.81
6.92
'19.70
15.15
81
8.62
19.70
16.75
_
81
&62
19.70
.1675 .MD
.81
7.50
2ZOO
Al
7.50
' 2 -00
17.50
81
750
22.00
19.50
.81
7.50
2200
19.50
.81
7.50 _
22.00
2320
.81
23.20
".81
7.50
�
27.95
.81
.7,50 22.00
27.95
I _
Fguro 3 ` 'itiT
C I D
12.05 3.50
13.05 3,50
14.40 4.50
15.40 ' 4.50
17.78 &25
1928 S 25
23.43 6.25
25.20 E25
26.52 7.00
25.15 7.00
28.02 7Ao
28.65 7.00
29.65 8.00
28.15 &00
31,15 8.00
29,85 8.00
33.28 9.00
31.15 9.00
33.28 9.00
31.15 9.00
3&76 10.00
98.27 10.00
35.27 10.00
42.05 1tA0
38.30 11.00
44.05 .11.00
40,30 11.00
49.38 11.00
44.00 11.00
6438 11.00
49.00 11.W
CONDUIT BOX . .
V
Figure 4 '
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0.35
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5.83
0.35
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0.70
1.76
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12.68
0.70 2.95
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12.68
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1.30 3.55
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1.30 3.55
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9.23 14.50
9.30 f 4.50
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10.29 16.20
10.29 16.20
11.04 10.20
11.04 1 16.20
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6312 1 6212
6312C3 6212C3
5312 6212
5312C3 6212C3
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3313 6213
3312C3 52120
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Note:
1. Dimension D iolerance; +0.00 inch -0.03 inch (143T-365T); +0.000 inch -0.06 inch (404T-44M. 4, Dimension V Is the length of straight part of shaft.
2. Dimension U tolerance: +0.000 inch-0.0005 inch (143T.21 M, + 0.000 inch -0.001 (254T-449T). 5. Bearing with mark': Grease pre -packed shielded
3. Dimension R tolerance: +O.O Inch --n n1 f. Inch „•,_,, ,r,

Performance and Construction Features
• Full cast iron construction: frame, end -brackets, fan
cover and conduit box (900 rotatable)
A Corrosion resistant external fan
A Stainless steel nameplate
A Shah slinger
A Zn plated hardware
A Oversized vacuum degassed steel bearings
A Lead lugs on 143T to 449T frame
A Clearly numbered leads
A Neoprene lead separator
A F-1 and F-2 mounting interchangeability
1 Accepts C-face (140T-449T), D-flange and P-base
(250T-449T) kits
A Efficient close -high -fin design
A High grade, insulated electro-magnetic steel
laminations
Dynamically balanced die-cast aluminum rotor
A Class F non -hygroscopic insulation with class B
temperature rise
1.15 service factor
�► Suitable for 208 volt operation through 125HP.
Part winding start capability at low voltage from
3/4HP to 125HP
A Wye -delta start capability from 71hHP to 250HP
(12 leads for 71/2HP--125HP, 6 leads for
150HP -- 250HP)
Fully tested and documented per IEEE 112,
Method B
TECO AMERICAN VVG
The last word in performance.
6877 WynnwoW Houston, Texas 77008
HOUSTON. TX LOS ANGELES, CA SPARTANSURG. SC ALLENTOWN. PA PORTLANO. OR
7131864.5980 7141870.2722 8031576.0356 215/391.9690 5031684.3363
For technical assistance or more information, please contact your TECO representative, or call 1-8MU5E-TECO MAR.'95/TA$039

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10.12. FEED ASSEMBLY:
10.12.1. Drawings: Feed Assembly

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10.13.
10.13.1- Drawings:
a. Horizontal Grid Assembly
b. Chicane Group Assembly
c. Upper Sludge Restrainer Assembly
d. Vertical Wedge Assembly
10.13.2. WQar Strip Replacement:
Note: Replace wear strips before belt contacts metal support grid.
a. Shut down belt press drive.
b. Detension belts and shut down all belt functions.
c. Lock out machine controls.
d. Raise sludge side restrainers.
e. Pull out and dispose of wom wear strip.
f. Insert new wear strip and tap into place with rubber mallet.
Ensure chevron pattern is maintained.
g. Unlock controls and start hydraulic unit. Tension belts.
h. Lower sludge restrainers into place.
10.13.3. Sludge Restrainer Adjustment:
a. Loosen side bolts in supporting brackets.
b. Raise of lower restrainers until seals is touching the belt
c. Tighten bolts.
10.13.4. Seal Replacement:
a. Raise side restrainers.
b. Remove old seals and discard.
c. install new seals on restrainers.
d. Lower side restrainers and tighten bolts.
10.13.5. Vertical W&dge Adjustment: the opening or aperture may be
adjusted at both the top (inlet) and bottom (outlet). The ratio between inlet
and outlet openings should be approximately 2: 1.
M. . Ili- I I t
(1) Release the bearing screws (see photo).
(2) Adjust opening by displacing bearing housings by
turning the adjustment bolts.
b. IQv= (Outlet) Adj ri n
(1) Turn the adjusting nut clockwise to reduce the opening.
(2) Turn the adjusting nut counterclockwise increases the
opening.

pressure. (1) Carefully remove the Tension Nut to release the spring
(2) Tilt the wedge section open for maintenance.
(3) Block the wedge open to prevent it from falling which
could cause personal injury or equipment damage.
(4) Replace the wedge and tension nut prior to operation.
(5) Do not over tighten the tension nut. This is a built-in
safety feature to protect the machine from damage due to over pressure if an object or mass
will not pass through the outlet opening.

10.13.6. Chicane Adjustment:
a. HorizonjW Adjustmeni-
(1) Loosen bolt.
(2) Slide chicane to desired position.
(3) Tighten bolt.
(1) Loosen bolt.
(2) Rotate retaining ring until chicane is resting on belt
(3) Tighten bolt
10.13.7. Chicane 1&enlacements
a. Stop belt press and lock out controls.
b. Rotate chicanes off belt.
c. Knock out roll pin.
d. Remove old blade.
e. Insert new blade.
f. Install roll pin.
g. Rotate chicanes onto belt.
h. Resume operations

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10.14. WASH TATION:
10,14.1. Drawing�sf.
a. Lower Belt Wash Box Assembly
b. Upper Belt Wash Box Assembly
c. Wash Tube Cut Sheets
d. Nozzle Replacement Instructions
e. Nozzle Information
10.14.2. Seal Replacement Instructions:
a. Shut down belt press and detension belts.
b. Lock out control panel.
c. Loosen wash box bracket bolts and position wash box so that
seals are accessible.
d. Remove old seals and discard.
e. Press new seals onto wash box edge. Cut seal so that the edge of
seal flares out from the box edge at a 45 degree angle to the belt.
This flare helps reduce the over -spray.
f. Reposition wash box and tighten bolts.

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NOZZLE REPLACEMENT
INSTRUCTIONS
1 1/2 INCH BELT PRESS SHOWER
TOOLS REQUIRED
• Tapered Collar
i 1 1/16" Punch
• Small (1/8") punch
• Soft head hammer
PARTS
Retaining ring
• Gasket
• Nozzle
WARNING: Wear safety glasses
daring this process. Metal chips or
flying retaining rings could result
in eye injury.
NOZZLE REMOVAL
Step 1
Use an awl or pointed tool to pry one
end of the snap ring out of the retain-
ing slot.
Step 2
Grip the snap ring end with a needle
nose pliers and pull, the snap ring out
with a twisting motion.
Step 3
Remove the nozzle and the nozzle
gasket.
Fig. 1, Tools
Fig 2, Gasket placement
Fig. 3, Nozzle placement
y
LEADOW IN
m:F7NlAT1�1 - , A
i.

NOZZLE REPLACEMENT
Step 1
Clean the nozzle seat and the groove
for the retaining ring.
Step 2
Lay one nozzle gasket into the noz-
zle saddle (Ref. Figure 2).
Step 3
Lay one nozzle onto the gasket with
the fan opening 85 degrees to the
pipe center line (Ref. Figure 3). The
nozzle should be placed so that it
protrudes into the pipe.
Step 4
Set the tapered collar tool on the noz-
zle saddle with the recessed end over
the saddle (Ref. Figure 4).
Step 5
Insert one retaining ring into the top
of the tapered collar tooL
Step 6
Drive the retaining ring into the
recessed groove with the 1 1/16"
diameter punch (Ref. Figure 5).
Step 7
Remove the collar tool and seat the
ring with a small diameter punch
(Ref. Figure 6).
Fig. 4, Collar tool placement
Fig. 5, Ring insertion
Fig. 6, Setting ring

WASHWATER SPRAY
SYSTEM DATA
Spray Tube Oats
A SLUDGE PRESS BELT CLEANING SHOWER WHICH CAN BE
CLEANED DURING NORMAL PRESS PRODUCTION
Total cleaning of the flat spray nozzles is achieved by turning the hand wheel in an anti -clockwise direction.
The bristles in the brush dislodge any contaminents from the nozzles and wash these to drain through the now
open valve.
Turn the hand wheel in a clockwise direction to close the discharge valve and return to normal operation.
The supply water valve need not be operated during the cleaning operation.
Advantages
1. Use of fresh or re -cycled water.
2. Low water consumption.
3. Nozzle cleaning and dirt removed during press operation.
4. Interchangeable nozzles for variation of application normal size 1.0, 1.5. 2.0. 2.5, 3.0 and 4.0 mm.
5. Nozzle fixing completely secure against belt damage. nozzle collar welded to the pipe nozzle secured by hex
nut which is retained by lock tite plastic.
6. No additional space required either side of the machine to operate internal cleaning brush.
7. Complete construction of corrosion resistant stainless steel. pipe-316 valve-316 Brush
assembly--316.
S. Uniform drainage, of filter belts, due to the simple cleaning operation, eliminating blinded areas across
the belt.
ASHHRQQK
CORPORATION

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WASHWATER SPRAY
SYSTEM DATA
Spray 7L+be Data
Water Consumption
per Nozzle
U.S. gpm/nozzle
4.5 L 4.0 mm die nozzle
4.O
3, 0
3, 5
3.O
2.5
2.O
1.5 2.0
1.0
1.5
0.5
Psi
15 30 45 60 75 90 105 120 135 150
85
ASHBROOK
CORPORATIM'

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T-T F R
VM6 IWE I � 1 [III T
IL F ._

10.15. SCRAPER:
10.15.1. Drawing: Upper & Lower Scraper Assembly
MIUMIMOMIWIM
a. Shut down press.
b. Rotate blade away from roller.
c. Remove cover plate bolts and save bolts.
d. Remove cover plate and save cover plate.
e. Remove and replace scraper blade with new blade.
f. Replace cover plate.
g. Replace cover plate screws.

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10.17.
10.17.1. Belt Data Sheet: Attached
10.17.2. Belt Use Record Sheet: Attached
10.17.3. Belt Cleaning Instructions:
a. Run wash water and belt drive (no sludge or polymer) for a
minimum of 45 minutes per day of dewatering.
b. If additional cleaning is desired, apply mild soap directly onto the
belts or inject into the spray wash system for one hour.
c. Monthly, clean belts with a solution of mild soap and Clorox
bleach.
d. Wash belts with high pressure water (Optional)
Use a maximum of 1,500 psi water at a maximum of 1101 F.
10.17.4. Belt EZ& Procedures:
Name
(1) Clean around the puncture and allow belt to dry.
(2) Using scrap belt material, cut a patch to size.
(3) Coat area with marine epoxy and apply patch.
(4) Allow epoxy to dry before operating press.
Note: When using marine epoxy, ensure belt is clean and dry before applying epoxy.
Apply epoxy to both belt and patch as evenly as possible. Let epoxy thoroughly dry
before ORErating. Dewatering will not occur in an area coated with marine epoxy.
b. Belt Edge Fra3dng:
(1) Clean belt edge and allow belt to dry.
(2) Cut off excess strands.
(3) Apply marine epoxy and allow epoxy to dry.

Belt Data Sheet
1. Fiber:
2. Type:
3. Weave:
4. Weight:
5. Mesh Opening in Microns:
6. Tensile Strength (Warp):
7. Tensile Strength of . Seam:
8. Safety Factor of Belt:
9. Safety Factor of Seam:
10. Belt Edge Coating:
Polyester Monfilament
8065
Mod. Satin
35.25 oz/sq. yd.
Warp-0
Weft - 350
> 1560 pli
502.8 pli
31( @ 50 pli)
10 (@ 50 pli)
Acetone Based Plastic Resin
(Heat Sealed)
MM
ASHBKOOK

T_.r.
MACHINE SIZE -
CHINE SIN:
UPPER BELT
LENGTH:
LOWER BELT
LENGTH: ---------------------
DATE:
DATE:
BELT TYPE: _--- --------------
BELT NO: --------------
BELT TYPE:
BELT NO: ----------------------
WHY REPLACED:
WHY REPLACED:
MACHINE SIZE
MACHINE SIN:
UPPER BELT
T.FNC,TH_
LOWER BELT
T FATf7 rT-.
------------------
DATE:
---------------------
I DATE: _
BELT TYPE: ___--____-----
BELT TYPE:
BELT NO: _
BELT NO:
WHY REPLACED:
WHY REPLACED:
MACHINE SIZE
MACHINE SIN:
UPPER BELT
LOWER BELT
LENGTH: __-_ -_ ___ _______
LENGTH: ----------------------
DATE:
DATE:
BELT TYPE: _--------
BELT TYPE:
BELT NO: _
_
BELT NO:
WHY REPLACED:
WHY REPLACED:

Filter Belt Maintenance
as Recommended
by Belt Manufacturer
1) A weekly maintenance and cleaning of belts are recommended. This
can be done by using 16 oz. of dry detergent that can be purchased in
any typical grocery store, and an addition of 16 oz. of Clorox bleach to 5
gallons of water.
2) A washdown on a daily basis of clear wash water to remove any
polymer build-up and debris within the belt.
3) A wash down with mild soap can either be applied directly onto the
belts or fed into the spray wash system for a period of no less than 1-2
hours.
Note: A program of preventive maintenance would be of greater benefit to
the end user rather than using a harsh caustic chemical that can
damage to the belts as well as to the personnel cleaning the presses.

10.16. DRIvr TRArN..
10.16.1. Drmimis:
a. Motor Technical Data
b. Motor Data
c. Electrical Motor Data
d. Electrical Motor Dimensional Data
e. Manufacturer's Instructional Data
10.16.2. i ' n:
Note: Lubrication F uenc y -Primary Gears 10,000 hours.
a. Pdmaa
(1) Check oil level every 5,000 hours.
(2) Replace oil every 10,000 hours or two years.
(3) Repack bearings every 10,000 hours or replace if
required.
4 �._�IV 4 " IN
(1) Check lubricants and grease every 40 operating hours.

Service and Repair Instructions
Right -Angle Helical Bevel Reducers
Type K/KF66-126
Table of Contents
Introduction
Workmanship and Safety .........................1
ReplacementParts...................................1
Tools and Equipment...............................2
General Repair Procedure
Bearings.............:.....................................2
OilSeals...................................................2
Gears......................................................2
Flangesand Tenons................................2
Sealants...................................................2
Preparationfor Repair...............................3
Disassembly
InputDevice.............................................3
Output Shaft and Gear
.............................4
Bevel Gear and Shaft...............................4
Bevel Pinion and Shaft
.............................4
Assembly
Bevel Pinion and Shaft ............................ 5
Bevel Gear and Shaft ..............................7
Output Shaft and Gear KIKF66-76 .......... 8
Output Shaft and Gear K/KF86-126 ........ 9
Output Shaft and Gear KA/KAF66-126..11
Final Assembly......................................13
Lubrication Schedule..............................14
LubricationQuantities .............................14
Mounting Positions ..... ........................15
Bolt Tightening Torques .........................16
Service Addresses .................... Back Cover
9: T.
EURODRIVE
K-004-01
March 1989
Supercedes: Jan. 1989

Tools and Equipment
Tools, equipment, and material needed to repair the
SEWEurodrive helical -bevel gear u.:it will depend
on the unit size and type and the nature of the repair,
but may include:
1. Metric wrenches and sockets
2. Torque wrenches
3. Metric socket head wrenches
4. Punches and cold chisels
S. Snapring pliers
6. Hand and hydraulic presses
7. Lifting equipment
S. Pry bars
9. Soft and hard faced hammers
10. Wood or plastic blocks or wedges
11. Depth gauges, indicators, and feeler gauges
12. Sealants
13. Proper lubricants
General Repair
Procedures
Bearings
Bearings must be removed and installed on shafts by
pressing only on the inner race or in bearing bores
by pressing only on the outer race with a pressing
tool of the proper size. Do not hammer on any bear-
ing during installation or removal. To facilitate in-
stallation, the inner and outer races of taper roller
bearings can be heated to 80'C to 100'C.
Bearings used within the helical -bevel gear units
may be either grease or oil Iubricated depending
upon the mounting position. Bearings that employ
shields and/or external ethos rings arc grease lubri-
cated and must be packed with grease during as-
sembly.
Input grease lubricated bearings should have only
1/3 of their free volume filled with grease in order
to avoid overheating the bearing. For output bear-
ings and bearings with replaceable grease shields fill
to 2/3 of the free vol umc.
If reusing a grease lubricated bearing, thoroughly
clean the old grease from the bearing with an ap-
EPA
propriatc solvent prior to repacking. Only use a sol-
vent made especially for cleaning grease from bear-
ings. Gasoline Is not a suitable solvent.
When installing nilos rings or bearings with shields
they must be in the same position as when removed
from The gear unit.
Oil Seals
Shaft oil seals arc easily damaged by din, exposure
to solvents, and rough handling. The steal cases are
easily bent. Seals should be kept wmppcd and away
from the immediate work area until they are to be
installed Never muse an oil seal.
Shaft extensions with keyways should be taped and
care should be taken when installing seals over shaft
shoulders without chamfers to avoid damaging the
seal lip during installation. Seals should be installed
with sleeve-lype press Siting tools and an arbor
press to assure smooth uniform installation pressure.
Seals must be installed square To the shaft.
Prelubricating the seal lip and seal bore with the
same oil that will be used in the gearcase aid in the
installation of the seal.
A thin coal of anaerobic joint sealant on The seal out-
side diameter, especially those with an exposed steel
casing, will help assure a leak -free installation.
Gears
Removing and installing gears requires the proper
tools to prevent damage. Screw type gear pullers
should be used with care to avoid damaging the gear
teeth. On the larger gear units hydraulic presses are
required to change the output gear. To aid the instal-
lation of gears, heat the gears to 120'C to 140'C and
drop them into place on the shafts.
Flanges and Tenons
After disassembly, clean all mating flanges and
tenons of sealant and/or gasket material. Impecl the
mating surfaces for any damage resulting from the
disassembly procedure. File smooth any nicks or
raised areas. Failure to properly prepare mating stir -
faces may result in oil leakage in the repaired unit.
Sealants
SEW-Eurodrive uses various anaerobic sealants and
gasket sealants in the assembly of the helical -bevel
gear unit.

The output covets and flanges must be scaled with
LoctileTx 574, a liquid anaerobic sealant. All other
relating flanges and tenons can be scaled with any
good quality anaerobic sealant or RTV silicone
sealant that is designed for high temperature
automotive engine use and is impervious to the gear
oil. A gasket sealant should be used with all gaskes
to assure leak-fre. operation after repair.
Follow the sealant manufacturer's guidelines for ap-
plication and cur. time. All surfaces to be scaled
must be clean and free of oil and grease. Use the
sealant sparingly. Normally an 1/8 inch continuous
bead is sufficient to seal the treating surfaces. Apply
the sealant to the machined surface of the gear hous-
ing between the bolt holes and the inside (oil side)
edge of the housing. Any through tapped holes in the
machined surface must have the top threads of the
tapped hole coated with a suitable thread sealant. For
easy disassembly later be sure to ttse only a thread
Sealant on the tapped holes and not a thread locking
adhesive/sealant.
Preparation for Repair
Remove the helical -bevel gear unit from the driven
equipment. Rcmovc any sprockets, bell sheaves,
couplings, and keys from the input or output shaft
extensions. Clean the outside of the drive thorough-
ly before moving it into the work area.
Drain the oil from the gcarcase and discard the oil
appropriately. Do not reuse the oil. if the drive is still
warm, use extreme tarn when draining the oil as hot
oil can cause severe burrs.
Before disassembly inspect the input and output
shafts for nicks or damage caused by set screws,
clamps, etc. Smooth the shaft extensions with a fine
toothed file as necessary. It is generally a good idea
to completely wrap the shaft extensions with one or
two layers of plastic electrical tape to protect the
shafts as well as the hands.
a 9 n $a * 11 97 17 g as 7S u7 as 66 67 86 bl W IM 79 77 7a n
Typical Pans Breakdown View for KIKF66-126 (K/KF96 shown)
See appropriate Parts List for your specific gear unit.
Disassembly
Input Devlce
The helical -bevel gear unit may have a motor, input
cover assembly, C-Fate adapter, mechanical VSD,
etc. as the input to the gcarcasc. All input devices
are removed and replaced by the same procedures.
3
When working with the input device take care not
to damage the attached pinion. Pull the input device
straight out until the tenon is disengaged and then
swing the input device to bring the gears out of
mesh.
1. Support the input device so that it will not fall
when it is removed. Use of slings is recom-
mcnded.

2. Remove the bolts and/or nuts securing the input
device to the gearcase.
3. Place a sharp cold chisel on one side of the gear -
case where the input device flange mates with
the gearcase and strike the chisel sharply with a
heavy hammer to break [he seal. As soon as one
side separates, move to the otherside of the gear -
case and use the chisel and hammer to separate
that side.
4. Use slender pry bars to complete the separation
of the input device from the gearcase.
Output shaft and gear
5. Remove end cover #100 by removing the sock-
et head screws #101. It will be necessary to use
a sharp cold chisel and a heavy hammer to break
the seal between the end cover and the gearcase.
6. Remove the output flanges and/or scaling flan-
ges #16 and #85 by removing the socket head
screws items #14 and #142 respe-cuvcly. It may
be necessary to use a sharp cold chisel and a
heavy hammer to break the seal between the
gearcase housing and the output flanges and/or
sealing flanges.
On I JR7126 it will be necessary to remove clos.
ing flange #97 by removing the socket head
screws #96.
7. Turn the gearcase on its side so that the bevel
gear #3 is on the bottom side.
S. Support the output gear #6 with blocks between
the gcarcase and the output gear so that as the
Output shaft is pressed out the output gear does
not move.
9. Place the gearcase in a press and press the out-
put shaft out of the gearcase while supporting the
output shaft so that it does not fall.
10. After the output shaft has been pressed out, the
output gear can be removed from [he gearcasc.
11. Remove and discard the oil seals #9 (#10) and
#183 (#184) from the flanges. Also at this time
remove any snaprings #88, thrust washer #87,
shims #86, nilos rings #83 and #84, and closing
caps #89 from the flanges as rcquirod by the na-
ture of the repair.
12. Remove bearings #11 and #25 from the output
shaft #7 and/or from the flanges #16 and #85 as
]he case may be.
Bevel gear and shaft
13. Remove both closing caps #131 by placing a
sharp chisel or punch near the center of the clos.
ing cap and striking the chisel sharply to pu;tc-
lure the closing cap and pry out.
14. Remove snaprings #39 and #132, shims #38 and
#134, and thrust washers #133 and #137.
15.Tum the gearcase on its side so [hat the bevel
gear #3 is on the top side.
16. Support the bevel gear with blocks between the
gearcase and the bevel gear so that as the pinion
shaft #5 is pressed out the bevel gear does not
move.
17. Place the gearcase in a press and press the pinion
shaft #5 out of the gearcase while supporting the
shaft so that it does not fall.
18. Remove bearings #30 and #37, and nilos rings
#135 and #138 from the gearcase housing and/or
pinion shaft #5 as required.
Bevel pinlon and shaft
19. Remove snapring #115 and shims #116 or lock
nut #113 and locking washer #114.
20. Stand the gearcase on its end with gear #2 on top.
Suppon the gear #2 with blocks between [he
gearcase and the gear so that as the bevel pinion
shaft #3(#123) is pressed out the gear #2 does
not move.
21. Place the gear case in a press and press the bevel
pinion shaft #3(#123) out of the gearcase while
supporting the shaft so that it does not fall. Inner
race and rollers of bearing #42 and spacer #119
will eomc out with the bevel pinion shaft
#3(#123).
22. Remove gear #2, roller bearing, #45, snapring
#47, spacer #117 (if present), and outer race of
bearing #42.
Z3. Bevel pinion shaft:
2 piece
Remove snapring #125 and press pinion shaft
out of bevel pinon. Remove spacer #119, inner
race of roller bearing #42, and shuns #120 and
#121 from bevel pinion shaft.
1 piece
Remove spacer #119, inner race of bearing #42,
and shuns #120 and #121 from bevel pinion
shaft (Bevel pinion and shaft arc one piece).

Assembly
1. Oil all bearing bores before installing bearings.
2. Bevel piraon and bevel gear are matched and, if
required, muse br replaced as a =.
Bevel pinlon and shaft
2. Deiermine the shimming required for bearings
#42 and #45.
a) Make a spacer to the appropriate dimensions.
C
D-DA
i
IJ�menowrs in miilimeicrz
Geeissx
Sire
A
B
C-.m!
66
.
38
23.010
76
70
50
26.310
86
90
(6
35.510
96
95
72
46.310
106
130
100
•e.800
126
160
123
33.510
c) With the hand press apply slight pressure io
the stack while rotating the bearings. Shims
#120 are either added or removed until the
spacer #119 and the one made in a) are well
secured between the two bearings and the
bearings rotate with cast.
b)As shown, stack the bearing #42, spacer
#119, shims 0120, snapring 447, spacer made
in a), and bearing #45 in a hand press. Initial- 4
ly use 0.5mm shims #120 for K66-K106 and
m 0.7mshims #120 for K126.
Spacer
I
} i
45 47
47
119
--
42
Spacer 120
li9
i
120
0 T I 42
i
R
F i.
lIH4nd press
5

3. Press outer race of bearing #45 into bearing bore. 7. Bevel pinion
a. 2 piece
4. Install snapring #47 and push outer race of bear-
ing #45 against the snapring.
5. Press outer race of bearing #42 into place.
6. Determine the shimming required for bevel
pinion #3.
a) Place inner race of bearing #42 into position
and secure in place by means of an appropriate
clamp.
b) Mcasum the distance X in millimeters from
the face of the inner race of bearing #42 to the
centerline of the crass bore for shaft #5.
The difference between the value X and the
dimension inscribed on the bevel pinion #3 is
compensated for by means of shims #121. (X
must always be greater than the value shown
on the bevel pinion or assembly will not be
possible).
6
Install snapring #12i, and key R122 onto shaft
#123. Press on bevel pinion #3, install shims
#121 as determined in step 6, press on inner
race of bearing #42, install shires #120 as
determned in step 2, and install spacer #119
onto shaft #123.
If spacer #119 has relief it must be toward
bearing #45.
119
123
3
120
42
121
122
3
125
b. l piece
Install shims #121 as determined in step 6,
press on inner race of bearing 442, install
shims #120 as determined in step 2, and install
spacer 0119 onto shaft R3.
8. Place preheated inner race of bearing #45 in its
outer race.
9. Install key #43 in gear #2.

10. Place preheated gear #2 (and spacer #117 on
KIKF/K.A/KAF 126 only) in position and trap
with a wooden or plastic wedge. Slide bevel
pinion assembly into bearing bore and press
completely together.
Wedge 115
Arbor 3 45 2 116 114 113
I
r
11. After bearing races and gears are completely
cooled down:
a)K66-86 - Install shims #116 to eliminate any
free float and install snapring #115.
b) K96-126 - With gear#2 blocked so that it does
not rotate, install locking washer 0114 and
lock nut #113 and tighten securely. Secure nut
in position by bending over a tang on locking
washer.
Bevel Gear and Shaft
12. From the gear reducer nameplate, determine the
mounting position. The mounting position
designation consists of a series of letters and
numbers with the suffix letters A and B to indi-
cate output shaft and/or Dange position. When
looking at the helical -bevel reducer from the end
opposite the input side, the right hand side is A
and the left hand side is B.
0
7
In the standard assemblies the bevel gear is always
on the opposite side of the gear reducer from the out-
put shaft and/or flange position.
Output Flange Bevel Gear
Gearcase Shaft At At At
K, KF A A B
K,KF B B A
K double
extended A&B - B
shaft'
KFF A&B A&B B
KA - - B
KAF - A B
KAF - B A
13. Install key #31 in keyway on pinion shaft #5.
14. Place the preheated bevel gear inside the hous-
ing on A -side or B-side as determined in step 12.
Then slide pinion shah #5 into bevel gear.
NOTE: Bevel pinion -and bevel gear are
matched and, kf required, most be replaced as a
15. For mounting positions V5, HS, and V1 install
ttilos ring #135 on pinion shaft #S.
16. For mounting positions V6, V1I, and H6 install
nilos ring #138 on pinion shaft d5.
17. Slide the preheated inner races of bearings #30
and #37 onto the pinion shaft #5.
30 4 31 5 37 Arbor
18. Press the outer races of bearings #30 and #37 into
the housing.

19. After the bevel gear and bearings are complete -
Iv cooled down set the circumferential backlash
(tooth clearance) of the bevel gear set to the ap-
propriate value. Install shims #38 and #134,
thrust washers #133 and #137, and snaprings #39
and #132 on both sides in such a way to achieve
the prescribed backlash. With proper backlash
setting, sufficient shims are installed so that the
snaprings can only be installed with d0culty.
131 132 133 134 38
137 39
Gearcase
Size
Circurnfcrendal Backlash
(tooth clearance) (mm)
66
0.08-0.11
76
0.08-0.11
86
0.10-0.13
96
0.10-0.13
106
0.12-0.14
126
0.14-0.17
20. Install closing caps #131.
KJKF66 and 76
Output gear and shaft
21. Jam the bevel gear with a wooden or plastic
wedge to prevent rotation.
22. Install key #19 in keyway on output shaft #7.
8
23. Place preheated gear #6 into position inside the
housing and slide shaft #7 into gear #6.
7 19 6
24. Rotate the housing on its side and support the
shaft 97 as shown.
16
Arbor
11
17
Mandrel
25. Install spacer #ft
26. Press on bearing #11. Be sure to prelubricatc the
bearing before installation.
27. Install sealing flange or output flange #16 and
secure with the socket head screws # 14. (Provide
surface scaling).

28. Turn housing upright. Press on bearing #25. Be
sure to prelubrieate the bearing before installa-
tion.
89 88 87 86
AW
85
For single shaft extension
29.InstaIl sealing flange #85 and secure with the
socket head screws #142. (Provide surface seal-
ing).
30.Install shims #86 to eliminate any free float,
thrust washer #87, and snapring #88.
31. Install closing cap #89.
32. Install oil seals #9 (#10) in the sealing flange or
output flange #16.
For double shaft extension
29. Determine the required number of shims #86.
a) Measure the distance from the housing seal-
ing surface to the face of the bearing #25.
b)Measure the distance from the flange sealing
surface to its bearing locating shoulder.
e) The di(rcrcnce between the distances in a) and
b) is the amount of shims #86 required.
30. With the appropriate number of shires 486, in-
stall the scaling flange or output flange #85 and
secure with socket head screws #142. (Provide
surface scaling).
8
31. Install oil seals #9 (#10) and #183 (#184) in the
scaling flanges or output flanges #16 and #85.
K/KF 86-126
Output gear and shaft
21.lam the bevel gear with a wooden or plastic
wedge to prevent rotation.
22. Install key #19 in keyway on output shaft #7.
23. Place preheated gear #6 into position inside the
housing and slide shaft #7 into gear #6.

24. Install spacer 917, nilos rings 083 and #84, and
preheated inner races of bearings #11 and #25
onto output shaft #7.
25 84 7 19 6 17 83 11 11
25. Press outer race of bearing #11 into sealing
flange or output pange 916.
26. Install sealing flange or output flange #16 and
secure with socket head screw #14. (Provide sur-
face sealing and lubricate bearing).
For single shaft extemion
27. Install scaling flange #85 and secure with sock-
et head screws #142. (Provide surface scaling).
99 58 87 86 25 85
10
28. Lubricate the bearing #25 and install the outer
race of bearing #25 into the sealing flange #35.
29. For K/R'FS&106
a) Install the shims #86, thrust
16 9(10) washer #87, and snapring
088. Use sufl :ient shins so
that the snapring can only be
installed with difficulty.
b) install closing cap #89.
29. For K/IL'>=126
a) Determine the required nutn-
"`i" ber of shims #86.
1) With the outer race of bear
ing #25 in place, measure
the distance from the hous.
ing sealing suface to the
face of the bearing #25.
2) Measure the distance from the closing flange
#97 scaling surface to its bearing locating
shoulder.
3) The difference between the distances in a)
and b) is the amount of shims #86 required.
b) With the appropriate number of shims #86, in-
stall the closing flange #97 and secure with
socket head screws #96. (Provide surface seal-
ing).
30. Install oil seals #9 (#10) in the scaling flange or
output flange #16.

For double shalt extension
27. Dctcrrrt ne the required number of shims #86.
a) With the outer race of bearing #25 in place,
measure the distance from the housing sealing
surface to the face of the beating #25.
b)Measure the distance from the flange #85 seal-
ing surface to its bearing locating shoulder.
e) The difference between the distances in a) and
b) is the amount of shims #86 required.
?S
28. Instal the appropriate number of shims #86 and
press outer race of bearing #25 into sealing
flange or output flange #85.
29. Imiall sealing flange or output flange #85 and
secure with socket head screws #142. (Provide
surface scaling).
30. Install oil seals #9 (#10) and #183 (#184) in the
sealing flanges or output flanges #16 and #85.
KAJKAF 66-126
Output gear and shaft
21.1am the bevel gear with a wooden or plastic
wedge to prevent rotation.
22. Install key #19 in keyway on output shaft #7.
11
23. Place preheated gear #6 into position inside the
housing and slide shaft #7 into gear #6.
19

24. Rotate the housing on its side and support the
shaft #7, as shown.
t
16
I 7
r I �
11
17
25. Install spacer #17.
26. Press on tearing #11. Be sure to prelubricate the
bearing before installation. For K.A/KAF 106-
126, install nilos ang #83 before installing bear-
ing #11.
27.Install scaling flange or output flange #16 and
secure with the sockeI head screws 014. (Provide
surface scaling).
28. Turn housing over and press on bearing #25. Be
sure to pmlubricate the tearing before installa-
tion. For KA/KAF 106-126, install r ilos ring
#84 before installing bearing r5.
29. Determine the required number of shins #82.
a) Measure the distance from the housing scal-
ing surface to the face of the bearing #25.
b)Mcasure the distance from the range #85 seal-
ing surface to its bearing locating shoulder.
c) The difference between the distances in a) and
b) is the amount of shims #82 required.
95 91-94 9 10 85 82 25 . 10 9
12

30. with the appropriate number of shims #82, in-
stall the scaling flange or output flange #85 and
secure with socket head screws #142. (Provide
surface scaling).
31. Install oil seals #9 (#10) and f1183 (0184).
32. Install snapring N91, disc #92, lockwasher #93,
and hex head bolt #95 into the hollowshaft.
33. Install closing cap #95.
Final Assembly
34. Install cover #100 and secure with socket head
screws #101. (Provide surface scaling).
35. Install key #8 into keyway on output shaft 07.
13
36. Screw in evebolt, oil level and drain plugs, and
breather. See Mounting Positions chart For cor-
rect location of oil plugs.
37. Place input gasket #29, if required, in place and
install the input assembly. Secure input assemb-
ly with appropriate bolts and/or nuts.
38.Fill with proper lubricant. Sec: Lubricant
Schedule for recommended lubricants and ap-
proximate quantities.
39. Trial run and test for unusual noises and/or oil
leaks.

Lubrication
Schedule
AMBIENTr1
KIN
LUBRICATION AIR T8M-
VISCOSITY
GULF
CHEVRON
AMERICAN
MOBIL
SHELL
TEXAC
TYPE PERATURE
AT 40'C
OIL CO.
OIL CO.
OIL CO.
OIL CO.
OIL
CO.
RANGE
(eSt)
'F
APPROX
+104
Guff
Cl+evrpi
to
210
E.P.
Non -Leaded
SPARTAN
Mobftear
Shelf Omala
Merope
+32
LubricM
Gear Compound
EP 220
630
Oi 220
220
S 100
220
oIr
+77
Gum
Chevron
to
145
F-P.
Non -Leaded
SPARTAN
Mobilgear
Shelf Omala
Meropa
+5
LubCAM
Gear Compound
EP I so
629
Olr 100
150
S 60
150
Grease
GuNcrown
Caron
ESSO
Used for normal applicalion
Grease
Dura-L1th
Mullipurpose
Mobllux
Shell Alvania
MuNflax
temp. range -- 20'F to 250-F
E.P. No. 2
BEACON 3
Grease
EP2
Grease R 3.
EP-2
BEACON I
Ivlincral oils and greases should be changed every 10,000 operating hours or 2 years. Repack high speed (input)
bearings to 113 of the available free bearing space. Repack low speed (output) bearings to 2/3 of the available
free space.
Svnthedc oils and greases should be changed every 20,000 operating hours or 4 years.
Under severe operating conditions (e.g. high humidity, aggressive environment, large temperature fluctuations
or high ambient temperatures) shover oil change intervals are necessary.
t}Consult factory for ambient lernperaIures outside the ranges shown.
Quantity in (US) Gallons

Mounting Positions
K66 - K126
K66R.. - K126R..
63. 851 B611% 831.
I _E - FS 5. =F
1„ e
B6 188
f
aa6 ■• -
V5. V11
V6. VI/I
I1 1
•K66-K126 Reducers: B611 mounting positions
we non -ventilated.
Symbols'
Mcunlueg sWlaeg
OBellaire.
Plug
Q
0.1 • Lc+el Plug - Red
.
Dam Plug. Blue
KF66-KF126
KFUR.. - 147126R..
V1. V15 V11. V61V11 y B5. 656
G 492
851. 831B51 B511. B6111B511' 85i11. 881851i1
•KF66-KF126 Reducers:-8511, B61VE1511 mounting positions are
non -ventilated.
KA66 - KA126
KAAW 66R.. - KA/KAF 126R..
H 1
H2
H3-
H4
H5
H6
Alm-
r
'KA66-KAF126 Reducers: H3 mounting positions are
non -ventilated.
is

Tightening Torques for
Metric Threaded
Fasteners
Hex Head or Hex Socket Screws
(Normal Thread Series)
Thread
Torque Ob-in) for
Hex Head
Size
Grade
Grade
Grade Grade
Socket Wrench
4.8
6.8
8.8 10.9
Size (MM)
M5
27
40
53 75
8
M6
50
73
97 125
10
M8
115
170
220 310
13
M10
220
320
425 610
17
M12
-
575
760 1060
19
M14
-
895
1195 1680
22
M16
-
1400
1860 2610
24
M18
-
1930
2565 3540
27
M20
2725
3630 5135
30
M24
-
4715
6285 8850
36
M27
-
6990
9295 13275
41
M30
-
9645
12850 '17700
46
M36
-
16650
22150 31400
55
Oil Plugs
Thread I Torque in
Size
lb -in
M10x1
105
M12xl.5
175
M224.5
710
M33x2
1150
M42x2
1415
16

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10.18.1. SK000377 In -Line Mixer and Injection Ring
10.18.2. Mixer Cleaning Procedures:
a. Remove side plate.
b. Clean internals.
c. Replace side plate and tighten bolts.

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11.0 LUBRICATION INFORMATION
11.1 LUBRICATION SCHEDULE
11.2 LUBRICATION CROSS REFERENCE
WP97-10 Rev. 2

ASHBROOK WINKLEPiRESS
LUBM, CATION SCHEDULE
ITE"
Bearings
Pinion Gears
Primary Drive Gears
FREQUENCY
Every 100 hours
Forty hours
10,000 hours

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Installation, Operation and Maintenance Manual
for
Dissolved Air Floatation (DAF) Range
Covering:
UF5, UF10, UF20, UF30, UF40, UF50,
UF60, UF70, UF80, UF90 & UF100

Operation and Maintenance Manual for
RAID Range
1. Terminology........................................................................................................................................3
2. Unit description...................................................................................................................................3
3. Operation principle.............................................................................................................................5
4. DAF Piping & Instrumentation Diagram..............................................................................................
7
5. Application..........................................................................................................................................8
6. Technical Specification........................................................................................................................ 9
7. Inspection and Testing......................................................................................................................10
8. Materials of Construction.................................................................................................................11
9. Acceptance and Delivery...................................................................................................................11
10. Transport and Storage....................................................................................................................
11
11. Assembly.........................................................................................................................................12
12. Operating Instructions....................................................................................................................
12
13. Maintenance...................................................................................................................................14
14. Service.............................................................................................................................................15
15. Troubleshooting..............................................................................................................................16
FEI

1. Terminology
Flotation — A process in which micro bubbles of air (30-50µm) dispersed in water adhere to dirt
particles, creating the lifting effect required to carry the particles to the surface.
Flotation apparatus — A facility for waste water pre-treatment on the basis of flotation.
Dispersion — A mixture of substances, one of which is finely dispersed in the other one.
Emulsion — Two immiscible liquids one of which is finely dispersed in the other one.
2. Unit description
Main parts of flotation unit:
The DAF flotation tank (1), is designed to allow for optimisation of the following characteristics:
• Hydraulic retention time
• Surface/solids loading rates
• Volume loading
The DAF unit is divided into inlet section, flotation zone and sedimentation zone, including a trough
for floated and scraped scum withdrawal and outlet part — for more details see Section 3, Fig. 1.
The following description relates to the image overleaf. The Scraper Mechanism wipes the floated
scum from the flotation tank surface (1) into the offtake trough. The plastic skimmers (43) are
screwed to the steel brackets (42, 44) and are fastened to plastic chains (40). The skimmer position
against the chain is given by plastic rings (45) which are fixed by shaped washers (46) and stirrup
rings (45). The chains are stretched between plastic chain -wheels (38) embedded into bearing bodies
(39) through primary (36) and driven (37) shaft. To facilitate the chain movements they are led
through removable plastic guides (41). The unit is driven by an electrical gearbox (33), with torque
transmitted via lever (34) and rubber block (35).
The Recirculation Circuit recycles a proportion of the flotation tank contents thus returning effluent
saturated with air back to the inlet section. The circuit consists of recirculation pump(s) (2), suction
pipe (6) and discharge pipe. A check valve (10) and ball valve (12) are incorporated within the
discharge pipe to provide unidirectional flow and isolation. The discharge pipe work also contains a
pressure vessel (4) fitted with a pressure gauge (14) and a compressed air connection to a ball valve
(15) allowing blow off, or purge of excess air via rubber hose (18/2). Distribution hoses (18/1)
distribute recirculated and aerated water back to the front end of the flotation tank zone.
The Air Circuit supplies air at the required flow and pressure to the discharge side of the
recirculation pump. It consists of an inlet rubber hose (19) connected to the pressurised air source (a
compressor), solenoid valve (22), pressure regulator (25), rotameter (29) and an air check valve (32).
(Optional) built-in Laminated Blocks seated inside the flotation tank optimise the sedimentation
process and separate the flotation and sedimentation zones.
3

7r M c'7 n
n
C5
M cl) rq
V
iV
{V
`t

Optional Accessories: (out of the scope of the flotation unit delivery unless specified on quotation)
• Compressor — The UNIVERSAL 500-50D type, output 360 I/min, max. discharge 10bar is
recommended.
• Knife gate valve - (electrical or pneumatic actuation) to be located on the sediment removal
pipe work.
• Coil pipe flocculator provides retention time for chemical reactions.
• Static Mixer — is inserted into the coil pipe flocculator. The mixer serves for mixing the
incoming waste water with chemical agents.
• Chemical units — Dissolving and storage tanks for preparation of chemical agents.
• pH instrumentation and flow monitoring.
• Intermediate pump stations and balancing tanks.
• Pre-screening equipment.
3. Operation principle
See Fig. 1
Physical flotation:
Physical flotation can only be used for the effluent provided that it exhibits the following
characteristics:
• Floated material occurs by means of air dispersion.
• Effluent is pre-treated to remove gross solids.
• Effluent will settle out and form a sediment.
The flotation process is not intensified by any chemical agent in this case. The flotation unit is in
service condition, i.e. the flotation tank is filled with clean water, recirculation pump runs and the
pump discharge is aerated. The saturation vessel pressure ranges between 4 and 6 bar. The air
dispersion is visible on the surface of the DAF. The pre-treated waste water from the rotary drum
screen passes forward to the DAF unit.
The recirculated aerated waste water stream is taken from the pressure vessel by hoses to the inlet
sockets. The sockets lead into the inlet section (A) of the flotation area. The air saturated in the
waste water is released in the inlet zone as a result of the pressure change in a form of micro -
bubbles (size distribution approximately 30-50µm). A very fine air dispersion forms gradually over
the whole inlet section and the process of physical flotation occurs, i.e. a mist of fine air bubbles (1)
adhere to particulates (2) and the buoyant forces carry the particles up to the flotation tank surface.
5

A high volume of bubbles make the process extremely intensive and consequently a layer of floated
sludge is created on the surface.
Effluent that is free of particulates flows through laminated blocks (if fitted) to facilitate the
settlement process (3). Sediment settles out at the bottom of the flotation tank (D).
Pre-treated water (by flotation and sedimentation) overflows into the outlet trough (B) and flows
out of the flotation unit through the discharge pipe.
Floated scum is drawn from the surface of the flotation tank by a scraper towards the discharge
trough (C) and the sludge handling facilities.
Sediment is emptied periodically (via pneumatic knife gate valve if fitted) via the discharge point by
(D). The particles settled out in the inlet section (A) are withdrawn manually through the ball valve
(E) as required.
Attention:
The DAF can be operated without any chemical addition only if the waste water is able to be treated
by physical separation alone. That is, the pre-treatment within the DAF can guarantee a residual
value of suspended solids below the point at which damage to the recirculation pump occurs.
Fig 1:
9

Chemical -physical flotation:
In this case the flotation process is intensified by dosing a suitable coagulant and/or flocculant. For
this purpose chemical dosing equipment, storage tanks and make down units for chemical solution
preparation, are included to improve the performance of the flotation unit. Metering pumps are
mounted and draw chemical from the storage tanks and deliver at a controlled and known dose rate
to a reaction vessel. In this case, the DAF unit is supplied with a coil pipe flocculator which precedes
the flotation unit and is supplied to promote mixing of the incoming waste water with the chemical
solutions. These chemicals induce precipitation of the emulsified waste yielding sludge flocs which
are then easily separated by flotation.
The optimum chemical agents and their dose rates are specified in each particular case on the basis
of wastewater characteristics and raw effluent concentration.
Attention:The coagulant ferric chloride FeC13 should only be used if the DAF is constructed from
316L stainless steel.
4. DAF Piping & Instrumentation Diagram
The basic components and operation of the DAF unit connection are described earlier in Section 2.
For correctly controlled operation the process requires for the wiring of the recirculation pump (2)
with the solenoid valve (22) and float switch (52) in order for the pump to be inhibited and the
solenoid valve closed in the event of the float switch disconnection — see Fig. 2. This prevents the
recirculation pump operating below its suction head requirement thus mitigating against the risks of
cavitation damage and as a conservative measure, the air circuit closes at the same time.
7

Fig 2
Outler pre—treated water
Outlet sediment Inlet to flotation LJj J
LEGEND
Metal pipeline (stainless steel) —X— pipelines
Rubber pipeline (houses) X Devices and armatures
— — El. connection
As discussed in previous sections, it is also recommended that automatic sediment removal (D) at
certain time intervals is made available by making use of a gate valve (5) with either electric or
pneumatic actuation. Optimum time intervals may be determined under specific operating
conditions after a period of normal operation has elapsed. The inlet section desludge point (E) can
be discharged into the same line as (D) downstream of the gate valve (5).
5. Application
DAF is a process designed for the pre-treatment of concentrated waste water often originating from
food processing industries. Excellent results can be reached in meat processing plants, slaughter
houses, poultry processing plants, fish processing plants, dairy works and other operations giving
rise to oily or grease laden waste streams.
Flotation effectively reduces extractable contamination (fats and gross solids), however a significant
reduction in organic pollution is also possible as measured by falls in BOD5 and COD across the
process unit.
A general guide to possible removal efficiencies are given below:
0

Indicator
Physical flotation
Chemical -physical flotation
FoG
75%
90%
SS
75%
90%
BOD5
40%
65%
COD
40%
6S%
The values shown are for general guidance only; they have been established on the basis of
experience from previous installations of DAF units or from an evaluation of static laboratory tests.
Before any installation of a DAF system takes place, a complete understanding of technical
ownership and responsibilities must be in place between the scheme designer, equipment supplier
and civil and M&E engineering contractors in order to establish project roles and interfacing
between parties. The structural and civil aspects should include but not be limited to the location
where the process equipment is to be installed, levels and falls for sumps, sewer connections,
chemical resources and management areas.
The technical specification should cover the installation of individual process units, i.e. pumps,
mixers, waste water pre-treatment (rotary screens, screw screens etc), flotation unit, preparation
and storage tanks for chemicals, containers for screenings and flotation sludge, presses, conveyors,
etc.
Recommendation: Any atypical or difficult installations should always be consulted with the
manufacturer.
6. Technical Specification
The DAF unit is manufactured and supplied in the basic model range (Fig. 3):
OF-5
OF-10
O F-20
O F-30
O F-40
O F-50
Max. flow
m3/hr
5
10
20
30
40
50
Total capacity
m3
2
2.5
4.5
6
11
11.5
Working volume
m3
1.7
2
3.8
5.3
8
10
Surface area
mZ
1.8
2.7
5.4
4.7
4.7
8.5
Weight (dry)
kg
500
800
1000
1400
1600
1800
Weight (operating)
kg
2500
3300
5500
7400
11,100
13,300
Power
kW
4.37
4.37
5.87
7.87
11.37
11.37
Length (L)
m
2.7
2.7
3.9
3.4
4.4
4.4
Width (B)
m
1.5
2
2.3
2.5
2.5
2.9
Height (H)
m
2
2
2.2
2.6
2.6
2.6
Inlet (A)
DN100
DN100
DN100
DN200
DN200
DN200
Effluent outlet (B)
DN100
DN100
DN200
DN200
DN200
DN200
Floated sludge outlet (C)
DN100
DN100
DN200
DN200
DN200
DN200
Sediment outlet (D)
DN80
DN80
DN150
DN150
DN150
DN150
Please note: all diameters are European standard
9

O F-60
O F-70
O F-80
O F-90
O F-100
Max. flow
m3/hr
60
70
80
90
100
Total capacity
m3
12
15
17
19
24
Working volume
m3
10.8
12.5
14.3
16.3
22
Surface area
M2
9
10.3
11.7
10
13
Weight (dry)
kg
2000
2300
2600
2800
3000
Weight (operating)
kg
14,000
17,300
19,600
21,800
27,000
Power
kW
15.37
15.37
15.37
15.37
15.37
Length (L)
m
4.6
5.2
5.7
6.3
6.2
Width (B)
m
2.9
2.9
2.9
2.9
2.9
Height (H)
m
2.8
2.8
2.8
2.8
3.5
Inlet (A)
DN200
DN200
DN200
DN200
DN200
Effluent outlet (B)
DN200
DN200
DN250
DN250
DN250
Floated sludge outlet (C)
DN200
DN200
DN200
DN200
DN200
Sediment outlet (D)
DN150
DN150
DN150
DN150
DN150
Please note: all diameters are European standard
De -sludge point (E) in all cases through ball valve 2".
DAF unit maximum flow is for guidance only as each specific case must be assessed individually
according to effluent type and concentration.
7. Inspection and Testing
All parts are tested for build quality and accuracy before assembly of the flotation unit. After the unit
is assembled, the quality inspection is carried out, followed by hydrostatic testing of all welds and
joints.
Operation test:
• Quality and accuracy of scraper mechanism is verified;
• The recirculation circuit is tested with the unit loaded, i.e. tightness of all joints are tested at
service pressure and under air dispersion operation.
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8. Materials of Construction
The flotation tank is constructed out of 3mm stainless steel plate. The flotation unit legs and braces
are typically of 100x100mm or 100x50mm forms. The recirculation circuit pipe work and other
external pipe work used are of stainless steel (1.4301).
The internal and external surfaces of the DAF tank are impregnated and consequently inactivated.
Both impregnation and inactivation agents are thoroughly washed down before shipping.
The skimming chains, chain wheels, cam chain guides, skimming blades and laminated blocks (if
present) are made of plastic.
9. Acceptance and Delivery
The flotation unit recirculation circuit is always removed and disassembled prior to shipping and its
parts are individually packed. The manufacturer is responsible for the unit quality and completeness
but the customer is expected to check off the delivery items against the shipping manifest for quality
and completeness.
Accompanying documentation:
• Certificate of conformity.
• O&M manual for flotation unit.
• O&M manual for recirculation pump.
• O&M manual for electric gearbox.
• O&M manual for compressor (if part of delivery).
• Quality certificate.
• Delivery and acceptance certificate for the flotation unit and accompanying documentation.
10. Transport and Storage
The flotation unit transportation is usually provided by the supplier at the cost of the customer.
Offloading of the DAF unit must be determined by a trained and authorized banksman given the
weight and dimension of the tank.
The customer must ensure protection from weather and mechanical damage during storage on site.
Following delivery, the customer is responsible for the stored flotation unit.
11

11. Assembly
Mechanical and electrical assembly and installation is carried out by the supplier or his
subcontractor following a purchase order and contract.
Should the customer decide to carry out assembly and installation on his own it is recommended
that consultation with the supplier takes place to fully understand the requirements.
General rules for the flotation unit assembly:
• The unit may be reliably operated if it is protected from weather conditions and the ambient
temperature never drops below 0°C.
• The unit must be installed in horizontal position.
• The recommended minimum space between the unit and wall is 600mm. There must be a
space allowance for handling of the floated sludge from the side of the DAF unit and access
must be made available to control elements on the scum outlet trough and to the air nozzle
locations.
• The recommended height for the building is 1000 mm over the unit's maximum height.
• A valve must be inserted into the waste water inlet pipe to allow regulation of incoming
effluent; a check valve should be included to prevent back flow in the event that the feed
pump stops running.
• It is recommended that an access platform is installed beside the unit for operational
adjustments and monitoring water level, scum removal and the overflow weir.
• The DAF unit must be installed in a well ventilated area as harmful gases may be generated
by the process under normal operating conditions.
• The DAF unit should be installed in a well lit building.
• Necessary services for proper operation of the DAF unit include a mains water supply (3 bar
minimum) and hot water source (3 bar @ 70°C).
12. Operating Instructions
Commissioning:
• The flotation tank must be filled with clean water to a minimum level above the recirculation
pump suction point. The recirculation pump must not be operated if the water level in the
flotation tank drops below the suction point.
The recirculation pump is not designed for pumping effluent carrying gross solids therefore
it is imperative to follow the start-up sequence of the DAF with clean water only.
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• Before filling the tank the valves on the sediment removal pipe work (D and E) must be
closed.
• The operating height of the flotation tank surface is given by the overflow weir which must
be set so that the level reached is below the beaching area feeding the trough where floated
sludge is removed from the process (see Fig. 4).
Fig 4:
• Following this, the pressure vessel valves must now be in a fully open position.
• Both the suction and discharge valves associated with the recirculation pump should now be
fully open.
• It is then possible to start the recirculation pump and air compressor.
• The airflow must be regulated to the level shown by the flow indicator and the air pressure
set at a level 1 bar higher than the pressure vessel.
• The pressure vessel should operate in the range between 4 and 6 bar, a fine air dispersion is
formed in the inlet section of the DAF under these conditions —white water is generated.
Eventually the white colour should be seen to spread across the entire surface of the tank.
• The DAF unit must be run for a minimum of 10 mins.
• The feed line butterfly valve on the inlet to the DAF may now be opened and the feed pump
set to run.
• The flight and chain scraper mechanism should now begin operation (the gearbox
configuration should allow periodic scraping operation, e.g. 5 mins idle, 1 min scraping).
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Post service checks:
• Carry out daily checks on the pressure in the recirculation circuit and the amount and
pressure air at the inlet to the saturator. In case of deviation from the optimal values make
the necessary adjustments.
• Carry out periodic checks on the flotation tank level to observe whether the flotation scum
has been formed and is being skimmed off. The level of the outlet weir should be properly
set and pre-treated effluent should flow freely out the overflow.
• Every 2 hours the sedimentation zone at the base of the DAF must be de-sludged, the
opening time for sludge removal should be set at the default value of S seconds minimum.
The frequency and the time of the opening can be adjusted via the PLC if required.
• Check the sealing of any valves associated with de -sludge points on the DAF unit as loose
valves or fittings can cause the DAF tank level to fall.
The recirculation pump is not designed for pumping of untreated effluent. It is very important when
operating the DAF to avoid:
• Suction of any sediment should the frequency of sludge removal be set incorrectly.
• Suction of floated matter should the frequency of the scraper mechanism be set incorrectly.
• Suction of floated scum should the dose rates of chemical agents be set incorrectly.
Temporary shut down of DAF plant:
• Stop the feed pump.
• Stop the recirculation pump, compressor, de-sludging, scraper mechanism in this order.
Following shut down:
Carry out a visual check of the flotation tank level; in the event that the level in the tank falls, the de -
sludge valve or the check valve in the feed line may not be fully tightened.
13. Maintenance
The DAF unit is a reliable and robust process which requires the standard form of maintenance and
good housekeeping. Firstly, operators should carry out daily visual inspections of all hydraulic,
pneumatic and chemical pipe work connections.
Other routine maintenance operations are as follows:
• On a biweekly basis, the operation of the recirculation circuit should be inspected.
Effectively, the clarity of the liquid passing through all isolation valves in the pressure vessel,
hoses and valves in the flotation tank must be observed. This check should be carried out
during the normal operation of the DAF unit, consecutively for every single hose:
• Close both valves associated with the hose being checked and release one of the
hose ends.
14

Open the valve and check it and the hose for water clarity (water should be drawn
into a suitable container).
• Open the other valve and check the water for its clarity.
• Carry out the above operation with all the valves and hoses in the recirculation circuit. In
case any of the valves and/or hoses get frequently blocked, the pressure vessel must be
removed and cleaned out. The removal operation should be carried out by the manufacturer
or representative agent.
• Three times a day or as required, open the inlet section de -sludge valve (for 30s).
• On a weekly basis, drain the flotation tank down to the inlet pipework level and rinse the
sockets and nozzles by pressure washer (hot water is recommended if available).
• On a biweekly basis, before the DAF is shut down for more than three days, the whole
flotation tank should be drained down (ensure slow drainage so as not to flood the sludge
tank). Empty by tanker the sludge storage tank before this operation is carried out to ensure
that sludge is not washed back to the balance tank. The flotation tank must be rinse cleaned
and inflow socket interiors washed with warm water. It must be made sure that the water
temperature does not damage the built-in laminated blocks (if fitted).
When servicing the recirculation pumps follow the manufacturer's instructions. Copies of
service and maintenance instructions are included with the DAF unit documentation.
14. Service
WPL Limited provide both warranty and post warranty services. The post warranty service should be
ordered in a written form if requested. Details can be sought from WPL.
All spare parts are delivered upon order.
15

15. Troubleshooting
Problem
Possible Cause
Action
Water overflows to the
The overflow weir, which
Lower the overflow weir
trough for floated sludge
regulates the level in the
removal
flotation tank is set too high
Scraping blades do not
The overflow weir is set too low
Set the overflow weir higher
reach the floated sludge,
the level is low in the
flotation tank
Waste water feeding pump is
1.Set the overflow weir higher
out of service - no increase in
2. Switch on the waste water
the level
feeding pump
There is a leak on the desludge
Check the sealing of the sludge
valve
removal valve
Effluent feed pump is not
Switch on the waste water feed
running for extended period
pump and fill the missing volume
and the fall is caused by the
overflow of the air purge
volume
On the surface in the
No incoming air — the ball in the
1. Check the function of the
flotation tank there is no
flowmeter is set at the zero
solenoid valve
floated sludge (foam)
value
2. Check the pressure of the
incoming air; it must be lbar
higher then the pressure on the
manometer of the pressure
vessel
3. Check the function of the
compressor
On the surface in the
The pressure vessel is full of air
Open the ball valve of the
flotation tank , at the inlet
overflow of the purge air. After a
section large bubbles are
period of deflation, turn down
appearing
the valve, reducing the volume of
incoming air on the flowmeter
16