DERRICK EX, Maintenance & Operation Manual

Page 1: ...ental Applications Derrick Corporation 590 Duke Road Buffalo New York 14225 Phone 716 683 9010 Fax 716 683 4991 www derrickcorp com Oil Gas Applications Derrick Equipment Company 15630 Export Plaza Drive Houston Texas 77032 Phone 281 590 3003 Toll Free 1 866 DERRICK Fax 281 442 6948 www derrickequipment com ...

Page 2: ......

Page 3: ...TION Location Telephone Facsimile FAX E Mail Website Derrick Corporation 590 Duke Road Buffalo New York 14225 USA 716 683 9010 716 683 4991 Technical Service techservice derrickcorp com Derrick Equipment Company 15630 Export Plaza Drive Houston Texas 77032 USA 281 590 3003 281 442 6948 General Manager rerice derrickequipment com ...

Page 4: ......

Page 5: ...y time Information provided does not cover all details or variations possible with DERRICK equipment nor does it cover every contingency that may be met in conjunction with installation operation maintenance or troubleshooting of the equipment Should additional information be required or should situations arise that are not covered by this manual bring the matter to the attention of your local DER...

Page 6: ......

Page 7: ... application and equipment on which the vibrator motor is installed The weight is stamped on the motor nameplate When two vibrator motors are installed on a single screen frame the motors are connected to cause the motors to rotate in opposite directions for maximum G forces The vibrator motors must be operated at their rated three phase supply voltage Motors are available in both explosion proof ...

Page 8: ...es proper handling installation operation and maintenance Failure to follow installation and maintenance requirements may result in personal injury equipment failure or property damage Only trained qualified personnel should be involved in the installation operation and maintenance procedures All plant safety procedures must be observed Qualified personnel must be familiar with the construction in...

Page 9: ...in storage periodically check the integrity of the winding insulation using a megohmmeter Maintain a continuous record of megohmmeter readings and immediately investigate any significant decrease in insulation resistance OPERATING ENVIRONMENT Derrick vibrator motors are designed to operate in ambient temperatures slightly higher than 104 F 40 C If higher temperatures are anticipated please contact...

Page 10: ...g Mount 12733 00 002 14266 01 2 3 Junction Box Cover 12739 00 12739 00 1 4 Terminal Block Assembly 11006 00 001 11006 00 001 1 5 O Ring 5 250 x 0 070 G0003627 G0003627 1 6 Bearing Spacer 12742 00 14269 01 2 7 O Ring 7 90 x 0 070 PP1503 PP1503 2 8 Weights Outer Serial Number Req d Serial Number Req d A R 9 End Cover 12736 00 001 12736 00 001 2 4 01 May 09 ...

Page 11: ...t G0002020 Torque Wrench 200 600 ft lbs 3 4 Drive G0003026 Extension 3 4 Drive x 8 Lg G0003027 Deep Socket 3 4 Drive x 1 1 8 G0003028 Box End Wrench Offset 1 1 8 G0003030 Breaker Bar 3 4 Kit No G0002161 1 Bolt With 5 8 Socket Hd G0002020 Torque Wrench 200 600 ft lbs 3 4 Drive G0001941 Deep Socket 3 4 Drive x 1 7 16 G0002160 Hex Bit Socket 1 2 Drive x 5 8 G0002163 Breaker Bar 1 2 Drive 842 06 Box E...

Page 12: ...YING ELECTRIC POWER TO THE EQUIPMENT AND LOCK OUT AND TAG OUT POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE AND OR ADJUSTMENTS OF EQUIPMENT WARNING MOTOR MAY BE DAMAGED BY STORING IN A HIGH HUMIDITY ENVIRONMENT GREATER THAN 50 RH OUT OF SERVICE MOTOR S MUST BE STORED IN A LOW HUMIDITY ENVIRONMENT Motor Handling When lifting motor position lifting sling at the center of the motor case as shown DO ...

Page 13: ...o table below for hardware sizes for each motor When installing the bolts note that the 3 4 motor bolts are installed from the underside of the screen frame Figure 1 while the 1 bolts are installed from the top of the motor Both configurations require hardened washers under the bolt heads as well as under the Flex Loc nuts Part No Dimensions Motor Bolt Head Nut Size Wrench Photo 9903 04 1 x 4 5 Lg...

Page 14: ...d washer and Flex Loc nut on each bolt Use a hex key bit to restrain bolt head while tightening nut from underside of screen frame 4 For 1 bolt installation with bolt head restrained use a torque wrench with 1 7 16 deep socket to tighten nut to 400 ft lbs For 3 4 bolt installation position motor on screen frame and align mounting holes with screen frame Insert bolts without anti seize compound app...

Page 15: ...SURE THAT VOLTAGE AND FREQUENCY ARE WITHIN 10 OF MOTOR DATA PLATE SPECIFICATIONS WARNING ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE NEC AND ALL APPLICABLE LOCAL CODES FAILURE TO COMPLY MAY RESULT IN AN UNSAFE CONDITION THAT COULD INJURE PERSONNEL OR DAMAGE EQUIPMENT ENSURE THAT ALL ELECTRICAL AND CONDUIT CONNECTIONS ARE SECURE WARNING EITHER REMOVE SCREEN P...

Page 16: ...over tightening backnut To prevent over tightening stop tightening backnut when red seal begins to swell 4 Install two O rings over leads inside junction box slide both O rings into threaded hole in box and position one O ring at each end of threaded hole to suspend the leads in the center of the hole Note Be sure that O rings are properly installed as they prevent chafing of leads due to abrasion...

Page 17: ...EX SGX VIBRATOR MOTORS Figure 2 Motor Cord Connections to Terminal Block 01 May 09 11 ...

Page 18: ...eads through junction box cover 3 Match leads to power connector markings and connect leads to terminals as shown 4 Apply anti seize compound to front gland nut and install and tighten in threaded opening in cover 5 Install remaining gland components and tighten backnut only sufficiently to cause red seal to begin to protrude Do not over tighten backnut 12 01 May 09 ...

Page 19: ... install cover by engaging power connector plug and receptacle Note Be sure that connector halves mate easily and that O ring remains in place during assembly 8 Secure cover to junction box with four socket head cap screws and tighten to 250 in lbs 9 Check for proper fit between cover and junction box surface by attempting to insert a 0 001 shim between the two parts around the entire mating area ...

Page 20: ...onduit 2 Pass leads through junction box elbow and into junction box Figure 5 Thread front gland nut into junction box elbow and tighten securely Thread rear gland nut onto front gland nut and tighten securely Thread and tighten backnut onto cable gland Using wire nuts and electrical tape connect leads to corresponding wire colors inside junction box as shown Note In dual motor machines be sure to...

Page 21: ...EX SGX VIBRATOR MOTORS Figure 5 Dual Motor Connections Round Junction Box Figure 6 Junction Box Electrical Connections Dual Motor 01 May 09 15 ...

Page 22: ...al switch are brought out to terminals P1 and P2 in the equipment electrical junction box To wire the thermal switch connect leads from the external indicator and power source to terminals P1 and P2 in the junction box If the stator temperature becomes abnormally high the normally closed N C thermal switch contacts open Depending on the connection scheme the open contacts either turn off the indic...

Page 23: ... L3 and L2 to L3 WARNING TO AVOID SERIOUS PERSONAL INJURY BE SURE EQUIPMENT IS LOCKED OUT TAGGED OUT AND DE ENERGIZED PRIOR TO PERFORMING MAINTENANCE AND OR ADJUSTMENTS VIBRATOR MOTOR MAINTENANCE Maintenance Action Frequency Using a water hose clean process material from exterior of motor case Daily or as required Inspect motor cable for signs of deterioration or damage Each shift or as required U...

Page 24: ...are packed with Mobilith SHC 100 grease to prolong life Regardless of supplier bearings must be packed with this grease or equivalent Derrick does not recommend use of bearings from an alternative supplier EX MOTOR BEARING REPLACEMENT KITS Part Number Description Qty Bearing Replacement Kit G0001703 G0001696 Bolt Jack Hex Skt Hd M8 1 25 x 70mm Aly Stl 2 PP1097 BRG Bearing Vibrator 2 PP1503 O Ring ...

Page 25: ...orque Wrench 3 8 Drive 150 to 750 In Lb 1 G0008935 Driver Hex 6mm Male 6 063 L X 3 8 Drive 1 G0001700 Wrench Hex T Handle 5mm Alloy Stl 1 G0003126 Wrench Ratchet 3 8 Drive Ind Finish 1 G0008317 Socket Allen Bit 5mm Lg 3 8 Drive 1 G0002250 Grease Vibrator SCH 100 10 Oz Tube 1 Tools Required Following is a recommended tool list for use during the bearing replacement procedure Torque wrench 200 to 10...

Page 26: ...MAINTENANCE AND OR ADJUSTMENTS ARE IN PROGRESS WARNING TO PREVENT SERIOUS EYE INJURY OR PERMANENT LOSS OF VISION WEAR SAFETY GLASSES DURING THIS PROCEDURE Bearing Replacement The procedure below describes replacing the bearing on one end Repeat the procedure for the second bearing NOTE Remove vibrator motor from equipment before performing bearing replacement refer to Motor Removal and Installatio...

Page 27: ...may be installed in this position 4 Remove outboard eccentric weight s from motor shaft 5 Using a soft absorbent cloth remove excess lubricant from components Do not use compressed air for cleaning as this may drive contaminants into motor 6 Using a torch with a diffused flame gently heat spacer for no more than 10 seconds to approximately 200 230 F 93 110 C to facilitate removal 01 May 09 21 ...

Page 28: ...ket head cap screws M8 1 25x60 securing bearing mount to bearing housing 9 Locate two threaded holes that accept the two M8 1 25x70 socket head jack screws Jack screw holes are 180 degrees apart 10 Carefully thread jack screws into threaded holes in bearing mount being sure to avoid cross threading 22 01 May 09 ...

Page 29: ...excess lubricant from interior of bearing housing and inner bearing race Do not use compressed air for cleaning as this may drive contaminants into motor 14 Using a torch with a diffused flame gently heat inner bearing race for no more than 10 seconds to approximately 200 230 F 93 110 C to facilitate removal 15 Carefully remove and discard heated inner bearing race from motor shaft Using a soft ab...

Page 30: ...on motor shaft with collar toward motor body Using a bearing heater or a torch with a diffused flame heat inner bearing race to approximately 200 230 F 93 110 C 3 After heating inner bearing race slide bearing race onto motor shaft until shoulder of race contacts bearing seat in rear of cavity Fully coat surface of inner race with grease supplied with bearing replacement kit 4 Orient longer reduce...

Page 31: ...aring housing 6 After bearing mount has been sufficiently drawn into bearing housing remove the two jack bolts and install original socket head cap screws M8 1 25x60 into the six clearance holes Hand tighten screws 7 Using a torque wrench and 6mm hex bit alternately tighten all six cap screws to 250 in lbs Coat motor shaft with grease included in bearing replacement kit 8 Using a bearing heater or...

Page 32: ...correct defect and reassemble bearing in accordance with this procedure b Using both hands grip eccentric weight s and push and pull along axial centerline of motor assembly Shaft must have no more than 1 16 1 8 1 6 3 2 mm of movement If excessive axial movement is found disassemble motor as necessary to determine cause of problem correct defect and re assemble bearing in accordance with this proc...

Page 33: ... overload if inadequate see motor data sheet for load data Mounting hardware loose Check that mounting hardware is properly tightened Starter circuit overloads and trips Vibrating motion of motor and related components are restricted Check that shipping brackets have been removed or disengaged as required Check condition of float mounts Verify that solids are not preventing motion of the screen fr...

Page 34: ...ne frequency agree with motor data plate Frequency must be within 1Hz No electric power to one motor Check that supply voltage is connected to both motors Motors not synchronized dual motors only Incorrect electrical connections Confirm that electrical connections are in accordance with the instructions in this section Derrick vibrator motors run with higher surface temperatures than standard indu...

Page 35: ...Overload protection Amps 8 7 5 4 4 Data below is common to all model EX 50 vibrators Insulation class Ambient temperature Operating temperature code Maximum temperature rise Duty Thermal switch rating Thermal switch type Thermal switch temperature Power factor operations Efficiency running Service Factor NEMA design Ingress Protection Weight Hazardous location listed as Listing agency Hazardous lo...

Page 36: ...elay Amps 25 25 15 12 12 10 Overload protection Amps 10 10 6 5 5 4 Data below is common to all model EX 60 vibrators Insulation class Ambient temperature Operating temperature code Maximum temperature rise Duty Thermal switch rating Thermal switch type Thermal switch temperature Power factor operations Efficiency running Service Factor NEMA design Ingress Protection Weight Hazardous location liste...

Page 37: ...Amps 20 20 12 10 10 7 5 Overload protection Amps 8 7 5 4 4 3 5 Data below is common to all model SGX 50 vibrators Insulation class F Ambient temperature 55º C Operating temperature code T3C Maximum temperature rise 46º C by resistance Duty CONTINUOUS Thermal switch rating Pilot Duty 720VA 110 600VAC Thermal switch type Normally Closed Thermal switch temperature Opens 145º C Closes 140º C Power fac...

Page 38: ...n Delay Amps 25 25 15 12 12 10 Overload protection Amps 10 10 6 5 5 4 Data below is common to all model SGX 60 vibrators Insulation class Ambient temperature Operating temperature code Maximum temperature rise Duty Thermal switch rating Thermal switch type Thermal switch temperature Power factor operations Efficiency running Service Factor NEMA design Ingress Protection Weight Hazardous location l...