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Home My WebLink AboutWQ0039488_Modification_1_20210721Initial Review Reviewer Thornburg, Nathaniel D Is this submittal an application? (Excluding additional information.)* r Yes r No Permit Number (IR)* WQ0039488 Applicant/Permittee Camden County Applicant/Permittee Address P. O. Box 190, Camden, NC 27921 Is the owner in BIMS? r Yes r No Is the facility in BIMS? r Yes r No Owner Type County Facility Name Courthouse Area WWTP County Camden Fee Category Major Fee Amount $0 Is this a complete application?* r Yes r No Complete App Date 07/21/2021 Signature Authority Signature Authority Title Signature Authority Email Document Type (if non -application) Email Notifications Does this need review bythe hydrogeologist?* r Yes r No Regional Office CO Reviewer Admin Reviewer Below list any additional email address that need notification about a new project. Email Address Comments to be added to email notfication Comments for Admin Comments for RO Comments for Reviewer Comments for Applicant Submittal Form Project Contact Information Rease provide information on the person to be contacted by N B Staff regarding electronic receipt, another correspondence. ittal, confirmation of iptd othd .......................................................... ronc su_ - Name * Kimberly Hamby Email Address* kim.hamby@timmons.com Phone Number* 2526215029 Project Information ........ ................................................................................................................................................... ......... ............ .... .... ........ ... ... .... .... .... ... ... ... .... .... .... ... .... .... ......... ...... Application/Document Type* r New (Fee Req ui red) r Modification - Major (Fee Required) r Renewal with Major Modification (Fee Required) r Annual Report r Additional Information r Other O Modification - Minor C Renewal C GW-59, NDMR, NDMLR, NDAR-1, NDAR-2 r Residual Annual Report r Change of Ownership We no longer accept these monitoring reports through this portal. Please click on the link below and it will take you to the correct form. https://edocs.deq.nc.gov/Forms/NonDischarge_Monitoring_Report Permit Type:* r Wastewater Irrigation r High -Rate Infiltration r Other Wastewater r Reclaimed Water r Closed -Loop Recycle r Residuals r Single -Family Residence Wastewater r Other Irrigation Permit Number:* W00039488 Has Current Existing pernit number Applicant/Permittee* Camden County Applicant/Permittee Address* P. O. Box 190, Camden, NC 27921 Facility Name * Courthouse Area WWTP Please provide comments/notes on your current submittal below. Please note that this submittal is for a change of ownership (from Camden County to the South Camden Water and Sewer District as well as a minor modification for the replacement of a manual bar screen with an automatic micro -bar screen. At this time, paper copies are no longer required. If you have any questions about what is required, please contact Nathaniel Thornburg at nathaniel.thornburg@ncdenr.gov. Please attach all information required or requested for this submittal to be reviewed here.* (Application Form Engineering Rans, Specifications, Calculations, Bc.) 48012 - Submittal File combined.pdf 10.08MB upload only 1 RJFdocurrent (less than 250 W). Miltiple documents rust be corrbined into one RDFfile unless file is larger than upload limit. * W By checking this box, I acknowledge that I understand the application will not be accepted for pre -review until the fee (if required) has been received by the Non - Discharge Branch. Application fees must be submitted by check or money order and made payable to the North Carolina Department of Environmental Quality (NCDEQ). I also confirm that the uploaded document is a single PDF with all parts of the application in correct order (as specified by the application). Mail payment to: NCDEQ — Division of Water Resources Attn: Non -Discharge Branch 1617 Mail Service Center Raleigh, NC 27699-1617 Signature woo D. �a�by Submission Date 7/21/2021 Gmpxjoh!xjui!Joopwbujpo/ or-tec.com Tqfdjbmj{joh!jo!uif!eftjho!! boe!nbovgbduvsf!pg!nvojdjqbm!! boe!joevtusjbm!xbtufxbufs!! usfbunfou!frvjqnfou/ 51ui!Boojwfstbsz!2:91!.!3131 Date: 23-Mar-21 OR-TEC BLUE WHALE MICRO BAR SCREEN Proposal for Mr. David Credle Camden Co. NC Representative Mr. Gregg Hauser Clearwater Quote # 10602.r1 OR-TEC, INC. reserves all copyrights and information contained in this proposal and in all accompanying documents, specifications and drawings. This proposal and all such specifications, documents and drawings are submitted solely for your consideration and in confidence, and remain solely OR-TEC, INC’s property, are subject to recall by OR-TEC, and are not to be published, reproduced, copied in whole or in part, loaned or otherwise communicated to any third party without OR-TEC’s permission other than for the purpose of promoting OR-TEC and its products. Drawings accompanying this proposal are not to be used for construction purposes. or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com 23-Mar-21 CAMDEN COUNTY, NC ATTN: MR. DAVID CREDLE Dear David, Thank you for your interest in OR-TEC Micro Bar Screen. This is the updated proposal you requested for an OR-TEC Micro Bar screen for the Camden Co. WWTP. The only change to the proposal is a 3% per annum increase in price. The pricing is as indicated budgetary. Once the manual bar screen has been removed this screen can be installed in the existing channel/pit without the need for any civil work. The unit is provided with controls and level sending and is a complete headworks system requiring no additional equipment. The OR-TEC Micro Bar is completely unique screen because it can screen to openings of 2mm to while not blinding due to its tapered bar construction and penetrating rake teeth. It does this without a requirement for washwater or brushes to clean the screen. It is a self-cleaning screen. This US patented screen is manufactured in an ISO 9001 and ISO 14001 factory. It removes the vast majority of wipes, hairs, rags and plastics which will pass through screens with larger openings. This high removal rate vastly improves the rest of the wastewater treatment plants operation by reducing fouling of pumps, valves and other rotating equipment. Most plants find the clogging of pumps and other rotating equipment completely stops once the Blue Whale screen is installed. You can find additional information, photos and videos on our website http://www.or-tec.com/index/micro-bar-screen Thanks for allowing us to present you with this proposal. OR-TEC’s goal is to provide a complete high quality screening and compacting washing system not a collection of components with multiple suppliers. With that in mind Our systems are fully tested prior to leaving our factory Our frames, unit bodies, covers and fasteners are manufactured from stainless steel The motors and geardrives we use are of the highest quality and designed for wastewater’s harsh conditions or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com We can supply all the equipment required for a complete screening package and we support all equipment we sell for life We offer free phone service for operational questions, maintenance issues and troubleshooting for the life of the equipment. We ensure the plant operators are 100% supported and are confident their unit is always fully optimized and trouble free. We hope this proposal is helpful and are confident if you chose the OR-TEC Blue Whale Micro Bar Screen for your screening needs you will be completely satisfied in your decision. If you have any questions or require more information please let me know. Regards, Jim O’Leary ________________________________ Jim O'Leary Sales and Marketing Manager OR-TEC, INC. jim@or-tec.com o: 216-475-5225 (ext 15) f: 216-475-5229 c: 440-897-3920 or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com SCOPE OF SUPPLY The OR-TEC Blue Whale Micro Bar is completely unique screen because it can screen to 2mm while not blinding due to its tapered bar construction and penetrating rake teeth. This US patented screen is manufactured in an ISO 9001 and ISO 14001 factory. It removes the vast majority of wipes, hairs, rags and small plastics which will pass through screens with larger openings. This very high removal rate vastly improves the rest of the wastewater treatment plants operation by reducing fouling of pumps, valves and other rotating equipment.The unit is fabricated from stainless steel and is ready for operation when it arrives on site. It is provided in a custom built, completely self-contained, stainless steel tank with inlet and outlet flanges No wash water required No brushes required (1) OR-TEC Blue Whale Micro Bar Screen Model Number: MB6120 Type: Mechanically Cleaned Tapered Bar Screen Screen Opening: 2mm openings Application Peak Flow: 245 gpm Wastewater: Municipal Wastewater Loadings: 200 - 500 mg/L TSS Screen Angle: 75° Discharge: 2’-8” above grade Motor Rating: 1/6 hp, 230/480v, 3 phase 60 hz Material: Main Frame, Micro Bar rack array, Head Shaft, Rake Chain & Rake, Tail Shaft, Rake Chain Sprocket: 304 stainless steel or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com Screening Bar Array: Tapered Bars Head and Tail Sprockets: Machined, heavy duty Head Shaft Bearings: Heavy duty, grease-lubricated, adjustable, take-up bearing assemblies Tail Shaft Bushings: Heavy duty, lubrication-free, sealed graphite immersed phenol resin bushings Rakes: Penetrating rake teeth Rake Hinges: Cushion spring mounted with 60-90° backwards rotation capability Chain Roller chain Chain Tension: Zero static tension to reduce wear Chain Guides: UV stabilized UHMW Rake Scraper: Installed over discharge chute (Stainless Steel) Material of construction: All 304 stainless steel Certification: ISO 9001:2008 and ISO 14001 (1) Control Panel The control panel shall operate the screen and ancillary equipment. Control panel shall be a NEMA 4X 304 stainless steel enclosure, 230/460VAC, 3 phase, 60hZ and shall contain all electrical controls, wires, starters, terminals, relays, overloads, fuses and labels required for operation of the screen and ancillary equipment. The system shall be fully operational in both manual and automatic modes. 1. Provide complete panel assembly, wiring, and testing services. 2. NEMA 4X 304 Stainless Steel Enclosure 3. Non-Fused disconnect switch with thru the door handle 4. HOA switches to control screen and compactor 5. Motor Starters with fusing and overloads 6. Selector Switches and pilot lights 7. Control transformer with fusing 8. 1 lot terminal blocks and related accessories or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com 9. Selector Switches 10. Electronic Over Current Relays 11. Elapsed time meter 12. Lot, control relays, terminal blocks and related accessories 13. E-stop mushroom red pushbutton with twist reset 14. UL 508 rated enclosure suitable for wall mounting 15. Dry contact outputs for Screen Run, General Fault, Over Current (1) Ultrasonic Level Sensor Ultrasonic level sensor mounted in channel upstream of screen. Power and controls provided by screen control panel. (1) Delivery to site (1) Shop Testing, Start-Up Services and Training (1) Warranty 12 months or 18 months from delivery, whichever comes first Total Budget Price……………………… $66,950.00 Notes: Delivery: 12 - 18 weeks upon written approval of relevant submittals Prices quoted are valid for 90 days Standard Terms and Conditions Attached or-tec inc 14500 industrial ave south cleveland oh 44137 usa or-tec.com p 216-475-5225 f 216-475-5229 info@or-tec.com INDEX A.INSTALLATION INSTRUCTION 1.General 2.Inspection Prior to Installation 3.Preparation Prior to Installation 4.Installation Procedures 5.Installation of Screen 6.Installation of Panel and Cable wiring 7.Installation Inspection & Start Up 8.Appendix B.Standard Instruction for the Chemical Anchor Bolts C.Installation of Accessories D.Operation& Maintenance Instruction 1.Operation 1.General 2.Inspection Prior to Start Up 3.Start Up E.Maintenance 1.Tension Adjustment of Rake Travelling Chain 2.Checking the Driving Parts & Lubrication 3.Instruction For Lubrication & Lubricants 4.Motor Faults 5.Regular Check Points & Time Frame F.Control Panel G.Attachment A.INSTALLATION INSTRUCTION Micro Bar Screens 1. General Those who are involved in the installation of the Micro Bar Screens should read this instruction and review the related drawings very carefully to achieve the best results and ensure the safety of personnel and the unit. Most mishaps during installation and start up of the unit can be prevented by using the correct lifting equipment and preventing any unexpected inflow of the wastewater during the installation work. 2. Inspection prior to installation Micro Bar Screens are shipped after a thorough inspection. However, below listed points should be confirmed prior to the installation as there might be discrepancies between the drawing and the actual site dimensions, and as the unit might have been affected by any impact or vibration during the transportation and the storage. (1) Is there any issue for the truck or the crane to access to the final installation point? (unstable ground, physical obstructions, etc.) (2) Do the dimensions between the actual wastewater channel and the drawing coincide? (Width and depth of the channel, flatness of the channel bottom and the wall, position of the screen pit etc.) (3) Is any part of the unit damaged or are any fasteners loosened? (4) Do all the descriptions in the name plate match the ordered specification? (5) Is there any omitted accessories or parts? (6) Is the shut off time of the wastewater to the channel during the installation sufficient? Is the cleaning of the channel easily accomplished? (7) Is the unit secured at all points? (8) Is the power supply for the installation secured? Is the power supply for the operation of the Micro Bar Screen secured? (Superfine screens of 1~10mm openings should not stop operations whenever there is flow. Continued inflow while the machine is not ud operating may cause overflow conditions and may overload the machine leading to mechanical breakage.) (9) Is there any interference between the Micro Bar Screen and the surrounding equipment? (10) Are there any other points that will be required for the installation? 3. Preparation prior to installation (1) Be prepared with the drawings for installation, and make sure all individuals involved in the installation are prepared. (2) Make sure the tools and equipment required for installation are available. (3) Make sure the power supply for the installation and the power supply for the operation of the Micro Bar Screen is ready. (4) Secure and clean the access way to the installation point. (5) Secure and clean the unload point of the unit and secure the space for the crane work. (6) Check and prepare the unit mounting point at the channel. (Inflow to the channel should be completely secured. Engineering controls safeguarding against sudden inflow of wastewater should be case put in place.) (7) Perform the foundation work. (8) Number of individuals, tools and equipment required to perform the installation. A. Individuals required Manager for the installation : 1 Supervisor, if required : 1 Individuals for installation: At least 1~2 person excluding the crane operator and electricians. B. Tools and equipment (This listing is for reference only) Crane (or Fork Lift): 1 (Number and Tons of the equipment to be decided by the manager. Sufficient tonnage of the crane required should be considered) Argon gas type Welder : 1 Arc Welder : 1 vd Impact Drill and reel cable : each 1 High speed wheel cutter 14” : 1 Standard hand tool sets : 2 Tools for electrical wiring and shield piping : 1 set Safety tools : Required sets for all workers Handspikes of over 2’ length : 2 Level : 1 Extra. tools and equipments to be prepared as per the site situation and the screen size. 4. Installation Procedure Check and prepare the unit mounting point at the channel Foundation work and marking Installation of screen in the channel Installation of Control Panel and cable wiring (Should be done prior to the installation of the screen in case of the existing channel and water shut down time is limited!) Final Check Inspection 5. INSTALLATION of the SCREEN wd (1) Installation of the Mounting Kit (Post) on the concrete floor is recommended to be done at least 1 day prior to the actual installation of the unit. In the event that it can only be done during the installation of the unit, the fact that hardening of the chemical anchors will take time of 2~3 hours normal, and may take over 12 hours in the winter time, should be considered. Installation on any structural beam can be simply done with mounting bolts. (2) For installing the chemical anchor bolts of the Mounting Post to the concrete floor, the ‘Instruction for the Chemical Anchor Installation (refer the attached appendix)’ should be very carefully referred. At first, mark the bolt holes points of the Mounting Post on the concrete floor confirming the exact position referring the drawing. Clearance “C” between the back of the unit and the corner of the back wall or the screen pit (MB Assembly DWG.#1 on page 9) should be checked carefully (There should be a gap.). If the approval drawing does not match to the actual site, the installation should be done after the confirmation of the superintendent of the whole construction. After the confirmation that the chemical liquid is hardened, locate the Mounting Post at the correct position and fasten the nuts loosely. Complete tightening is recommended to be done just before the installation of the unit. (3) Placing the unit into the channel should be done by the crane, and extreme care is required so as not to cause any damage or torsion to the unit. Uneven lift force to the eyebolts of both sides can cause the distortion to the parallel confrontation of the side- xd frames, which can make the rake and the bars not align properly, and this will cause severe damage to the screen. So please be sure that the crane hook is positioned at the center of the whole sling length before lifting. (Remarks: Slings or sling shackles of the crane should never be positioned except at the designated eyebolts.) (4) At first, fasten the nuts of the mounting post tightly to the chemical anchors. Then lift the unit up by crane and insert into the channel. Attention should be paid so as not to spoil the rubber sealing of each side frames during the installation of the unit. (5) Screen pit should be long enough to have allowance at the front part of the unit compared to the footprint of the front point of the unit (FPFU of Fig. 1). Contact the front point of the unit to the position 10” ahead of the FPFU at the channel bottom at first by the crane (Be careful that the bottom sealing rubber would not be pressed down under the unit). Then slowly lay down the unit to the Mounting Post to contact the back of the unit to the Sliding Bracket (18-2) which is fastened to the Mounting Post by the U-Bolts (Sliding Bracket should be prepared at the angle that can match to the unit back by loosening the U- Bolts a bit and the cross direction match of the bolt holes to the back of the unit should be checked also.). This makes the front point of the unit positioned 1/2”~2” above the channel bottom (Fig. 2). (6) Pull the unit up very slowly and little by little until one of the front point of the unit contacts to the channel bottom (should be checked continuously lifting the bottom sealing rubber up by hand.). Then fasten the bolts of the sliding bracket loosely after fitting the installation angle of the unit, the clearance between the back of the unit and the corner of the back wall (1”~2”), close contact of the bottom of each side frames to the channel bottom, horizontal match of the unit each by longitudinal and cross direction and the position of the end of the discharge chute (13), using the handspikes to the bottom of the front point of the unit side frames. And then, fasten the U-bolts of the sliding bracket tightly. (7) Next step is lifting up the unit again very slightly finally (less than ¼”) and then fasten the slide bracket bolts tightly. (Remarks: Any more lifting with the crane after this will hurt the chemical anchor bolts foundation!) Horizontality of the unit should be checked by a level both for the longitudinal and cross direction, and is very important for the long life of the unit. (8) If the contact of one of the side frames to the channel bottom is not good even all of the unit horizontality is perfect, the channel bottom should be fixed even inserting some sheets of stainless steel. If the horizontality of the unit is perfect, the two front edge lines of the side frames of the unit should be matched in one line when seen from the side of the unit. yd Matching these lines together along with the heights of the units when installing 2 or more units simultaneously is important too from the visual point. (Clients may request to reinstall to match the inclined angles of the units together.) (9) Chemical anchors should be installed on the Anchor Plate (1-1) (Prepared only when needed.) if the high-water level is over 1.5m while the overflow control is not provided. (10) In case of the very long unit which a Support pipe is described on the approval drawing at the middle part of the back of the unit, the support pipe should be installed contacted to the back of the side frames after all the setting of the unit installation is completed. In this case, Support pads should have been installed in advance at both sides of the channel walls by the chemical anchors, and both ends of the support pipe can be welded to the support pads. Supplied support pipe should be cut by the actual measurement between the support pads at the site. (11) After all the installation of the unit is finished, final touch up to any scar of the unit and the welded parts should be done. 6. INSTALLATION of the CONTROL PANEL & Cable Wiring (1) Install the Local Control Panel after the confirmation of the installation position and the route for the electrical cabling. Chemical anchors should be used for the panel installation, and if the mortar base is required, it should have been done previously, the wiring work is recommended to be done in advance of the unit installation in the channel if the installation is for the existing channel (In case of the superfine screens of 1~10mm openings, screen should be cleaned continuously by the traveling rakes whenever the wastewater is flowing in.) The electrical wiring and the shield piping work should be done by the qualified electricians. (2) When wiring the power cables in the control panel and checking the rotating direction of the rake traveling chain (or the rotating direction of the motor shaft), the trial startup is recommended to be done by an instant contact of the wires of less than 1 second for preventing any damage of the unit even if the unit is designed to allow the reverse rotation. (3) Prime Check Points for the Micro Bar Screen Start Up a) Engagement of the rake teeth with the screen openings. zd Proper engagement of the rake teeth between the screen bars is very important for the long lifetime of the machine. Every rake should be checked one by one stopping the rake traveling for the accurate centering of the teeth between the bars, and for the deep penetration into the slots. If the engagement is distorted during the transportation and installation, careful adjustment should be performed unscrewing the rake nuts slightly. b) Horizontality of the unit. If the horizontality of the unit is perfect, the two front edge lines of the side frames of the unit should be matched in one line when seen from the side of the unit, and this is very important factor for best digging of the rake teeth into the screen openings and for the long life of the machine. c) Horizontality of the traveling rakes (16). (=Tension of the traveling chains (17) of the both sides) {d The Ascending Rakes to the Bar Support Beams should be parallel, this is very important. This should be adjusted in driving condition by turning the Take-Up Bolts (11) gradually, and Descending Rakes can be disregarded comparatively. Be sure that the tension of the traveling chains should never be tightened fully. |d }d 7. INSTALLATION INSPECTION and START UP (1) Inspection date for the installation and the start up should be appointed with the superintendent of the construction and the supervisor of the supplier. (2) Installation inspection is the inspection for the installation of the whole equipment, assembly status of the unit, any damage, and the painting status. (3) Start up inspection is done by unloaded or by loaded driving status. The driving direction of the unit, noise status, any trouble during the operation, tension of the traveling chain and etc. are checked during the unloaded drive inspection by driving the unit without the wastewater influent. And the Inspection Report for the Unloaded drive Inspection should be signed by the superintendent of the construction site. (If required, this report should be delivered to the supplier or to the contractor of the unit.) (4) Loaded drive inspection may be done subsequently after the unloaded drive inspection. Status of the operation and the capacity of the unit will be checked during the inspection. (5) If any fault is found during the inspection, any little fault can be fixed at the site and should be approved by the superintendent, but any larger issues should be reported to the supplier immediately and should be fixed as soon as possible with the utmost endeavor. Inspection should be done again in this case as soon as the problem is solved. 8. Appendix (1) INSPECTION REPORT for INSTALLATION & START UP (2) Installation Drawing (3) Standard Instruction for installing the Chemical Anchor bolts (4) Installation of the Accessories (5) Arrangement with the surrounding equipments utd INSPECTION REPORT for INSTALLATION & START UP Inspection Project Date Name of Installation Micro Bar Screen Equipmentsite RESULT Inspection ITEM Remarks standard PASS REJECT 1. Rotation of Drive Motor sight 2. Overheat, Noise and Vibration of Drive Motor sight & etc. 3. Any oil spill of oil from Drive Motor and Gear- sight reducer 4. Rake Traveling Speed Approved Spec. 5. Horizontality of rakes during operation? sight 6. Access of rake teeth between screen bars sight 7.Tension of the traveling chains sight & etc. 8. Any noise or vibration at overall unit? sight & etc. 9. Cleaning status of the unit sight & etc. 10. Parallel and horizontality of side frames sight 11. Installation angle of the screen sight 12. Operation of control panel and each lamps sight 13. Interlock with up & Down stream equip. sight 14. Ampere check of the drive motor sight or meter Supplier Superintendent uud B. STANDARD INSTRUCTION for the CHEMICAL ANCHOR BOLTS 1. Standard Depth of Anchor Bolt Holes as per the bolt diameter. Anchor Hole Anchor Hole Size Diameter(mm) Depth(mm) M10 (3/8”) 12 (15/32”) 90 (3-1/2”) M12 (1/2”) 14 (9/16”) 110 (4-3/8”) M16 (5/8”) 18 (11/16”) 125 (4-15/16”) 2. Installation of Anchor Bolts a. Drill the anchor holes on concrete with the impact drill. b. (Hole diameter and the depth, as per the standard.) c. Clean the anchor holes with air or etc. d. Insert the chemical fluid tube into the holes. Be careful as not to break the tube glass. e. Insert the anchor bolts into the holes with an impact wrench or a hand drill with adapter. (Impact mode) f. Stay required setting time for hardening the anchor foundation. Setting time is as per below table. Ambient Temperature Setting Time Over 20°C (68°F) Over 30Min. 10 ~ 20°C (50 ~ 68°F) Over 50Min. 0 ~ 10°C (32 ~ 50°F) Over 2 Hours -10 ~ 0°C (14 ~ 32°F) Over 12 Hours < Remarks > 1. All the end of the inserting anchor bolts should be cut 45° inclined. 2. Any single force should not be applied to the bolts during the setting time. uvd C. Installation of the Accessories Accessories : 1. Level Sensors Level Sensors should be installed as per the measurements of the approved drawing. If the High and Low points are to be relocated, it should be confirmed by the supplier. 2. Local Control Panel Local control panel (LCP) should be installed close to the screen for providing the good view of the unit operation. Installation of LCP in advance of the screen installation is desirable. uwd D.OPERATION & MAINTENANCE INSTRUCTION Micro Bar Screens 1.OPERATION 1. General Those who are involved in the operation and maintenance of the Micro Bar Screens should read these instructions very carefully for achieving best efficiency and safety of the unit. Any accidents during operation and maintenance of the unit can be prevented with careful operation. 2. Inspection, prior to the start up. Below listed points should be confirmed prior to the start up. (1) Check if any hazardous gas is settled at the bottom of the channel or if the oxygen content is thin before any individual goes down to the wastewater channel. (2) Check for and remove unusually large quantity of debris that may have accumulated upstream of the screen. Gradual opening of the penstock is recommended for avoiding sudden rush of debris. (3) Check if the related equipments at the upstream and the downstream of the Micro bar screen are ready for startup also. And the surrounding equipments connected to the Micro bar screen, i.e. washer compactor or conveyor, should be checked whether they are ready for start up also. (4) Micro bar screen should be in operation in advance of the wastewater inflow as the superfine screens of 1~10mm openings should be cleaned continuously by the traveling rakes whenever the wastewater is flowing in, for preventing sudden overflow. uxd 3. Start Up (1) Turn on the circuit breakers of the LCP (Local Control Panel) after checking all the switches on the LCP are turned off. (2) Confirm the traveling direction of the rakes by enforcing the instantaneous ON & OFF cross switching of within 1 second on the push button lamp switches of FORWARD and STOP after setting the selector switches of LOCAL/CENTER to LOCAL, the MANUAL/AUTO to MANUAL, and the FORWARD/REVERSE to FORWARD. Raking up on the screen bar rack from the bottom to the top of the machine is the correct travelling direction (or as per the rotation mark indicated at the end of the drive motor shaft), and the wiring of the drive motor cable should be changed if the traveling direction is reversed. When changing the wiring direction of the motor, cut off of the power by the circuit breaker should be done in advance. Remarks : Traveling direction of the rakes should be checked again even though it was checked during the installation as the wiring can be changed from the main control center without notice due to the long period of construction. And the reverse traveling of the rakes of over 1~2 second is not recommended even the unit is designed to allow the reverse rotation. (3) Start up the screen operation again if the rake traveling direction is confirmed. Check if any abnormal noise as per below. (Need repeated start up and stop over 3 times.) a. Any vibration of the screen bars. b. Horizontality of the traveling rakes. c. Any abnormal noise when the rakes are scraped by the scraper at the top of the machine. d. Abnormal noise and heat of the drive motor. e. Over current of the drive motor. f. Operation status of each lamp on LCP. (4) Set the MANUAL/AUTO switch to AUTO position and see whether the screen operation is stop, then keep the AUTO mode status. (5) Open the penstock of channel gradually for avoiding sudden rush of debris which may have accumulated upstream of the screen. Be sure to check for and remove abnormally big or unusually large quantities of debris that may cause damage of the screen. Watch the automatic operation status of the screen as the water level goes up, and check the discharge status of the screenings to the conveyor or trash bin. Dry uyd content of the screenings discharged from the discharge chute of the Micro Bar Screen is 3~15% as per the influent, and dehydration by a compactor or time for dry is required for incineration or landfill. uzd E.MAINTENANCE 1. Tension adjustment of the Rake Traveling Chains. Rake Traveling Chains tend to be extended a bit in length after the 1 ~2 months of operation, and the tension is loosened. So, an adequate adjustment is required after checking the looseness of each chain. Chain tension can be tightened up by turning 0.5~2 revolutions the Take-Up Bolts at the top of each side frames, and the whole tension should be a bit loose just as we can see 15~20mm of suspension at between the Head Sprocket and the Entry Point of the chain guide rail. (Never set the chains stretched so tightly as this will cause severe loss of chain lifetime!) Remarks : Adjusting the tension of both side chains to be the same is very important for keeping the horizontality of the rakes and maximizing the lifetime of each mechanical parts. Horizontality of the traveling rakes. Parallel of the Ascending Rakes to the Bar Support Beams is very important. This should be adjusted in driving condition by turning the Take-Up Bolts gradually, and Descending Rakes can be disregarded comparatively. Be sure that the tension of the traveling chains should never be tightened fully. 2. Checking the Driving Parts and the Lubrication. (1) Gear Reducer of the Drive Motor Gear Reducer of the Drive Motor is filled with the lubricant and it is needed to be replaced at every 10,000hrs of driving. u{d (2) Head Shaft Bearings Check the head shaft bearing lubricant every 1 month, and needs to be lubricated until the grease is spilled out from the gap between the inner and the outer rims of the bearings. (3) Tail Shaft Bearings As the Tail Shaft Bearings of the Micro Bar Screen are the Graphite immersed Phenol Resin Bearing developed for the wastewater facility, any lubrication is not needed or recommended. 3. Instruction for the Lubrication and the Lubricants. Lubricant for Gear Reducer of the Drive Motor a. Overfilling of the lubricant will cause the spillover and may cause sealing problem of the gear reducer, so the proper filling by the designated guide is recommended. b. Recommended Lubricant Lubricants are recommended as per the separate instruction of Nord Drive System. 4. Motor faults. Micro Bar Screen is adopting the patented Hinge Cushion Mounted Rakes for protecting the mechanical parts instantly and repeatedly (without manual resetting) from any issues. However, if any big debris that cannot be covered with the hinge cushioned protection jams between the rake and screen bar rack, drive motor will be stalled, and the electric power to the motor will be cutoff with the audible alarm on the local control panel by the positive overload protection reading the excessive motor current. If this trip happens, Press the Boozer Stop Switch to stop the alarm buzzer sound. u|d Then check the problem and remove the jammed debris by turning on the Reverse switch within 1~2 second. Reverse driving or Forward driving can be enforced only after the FAULT/RESET switch is pressed (Be sure to set the selector switches of LOCAL/CENTER to LOCAL, and the MANUAL/AUTO to MANUAL before pressing the FAULT/RESET switch). Reverse traveling of the rakes of over 1~2 second is not recommendable even the unit is designed to allow the reverse rotation. Carefully check and restart the driving of the screen. 5. Regular Check Points and Time Frame. (1) Daily Check Any oil or grease spill? Any loosen bolts and nuts? Any noise at each point? Noise and abnormal heat of the drive motor. Any Vibration? Current of the drive motor. (2) Weekly Check Lamp operation of the LCP. Operation status and noise of scraper. Cushion mountings of each rake. Any tangle of rags or stringy materials at the cushion mountings of the rakes. (3) Monthly Check Any problem at the guide rails of the rake traveling chains? Lubrication status at the bearings and the drive chain. Tension of the Rake Traveling Chains. Corrosion status of each terminals and electrodes of the control panel. Corrosion status of the electrodes of the level sensor. (4) Quarterly Check Operation of the Local Control Panel and the components. u}d Alarm Light & Boozer, Limit Switch of Torque Limiter. Insulation of power cables and etc. (5) Half Year Check Abrasion of Rake Traveling Chains. Abrasion of Head and Tail Shaft Sprockets. Abrasion of Chain Guide Rails. Tension of the Drive Chain and abrasion status. (6) Yearly Check Replacement of lubricant for the Gear Reducer of the Drive Motor. Check and fill up or replacement of the grease for the head shaft bearings. Abrasion of the teeth of the rakes. (7) Winter Time Check (When heat tracing is applied.) Heat Tracing System shall be turned on manually in the winter time if the supplied control is not with the thermostat switch for preventing the freezing of the Dead Plate along with the Discharge Chute. And the operation mode should be set to “24hours continuous driving mode” for preventing mechanical breakage incurred by the freeze. REMARKS ! : All the repair and replacement operation should be done after turning the power of the main source and the control panel off, and after attaching the Notice Stickers of ‘Hands off’ to the Main and Local Control Panel. Any assistance for the service operation can be requested to, Or-Tec Inc Service Department. 216-474-5225 vtd