| S. No | Code | Fault | Cause | Corrective Action |
|---|---|---|---|---|
| 1 | D-19 | Pin Bush Coupling Failure | Load is very high | Reduce the load |
| Improper Start/Stop sequence | "The bucket assembly should be started five minutes before the feed is given. The buckets should run idly for a substantial period of time before the feed is given. Likewise the buckets should be stopped five minutes after the feed is stopped to the machine.The buckets should run idly for a substantial period of time after the feed is stopped. Failure to follow this protocol will engulf the buckets in the slurry that may settle once the machine is stopped. Starting the machine again will break the pin bush coupling or the gearbox." | |||
| Water is inadequate | Increase the capacity of pump / flow rate of the pump | |||
| Feed size is high | Screen the material to minus 5 mm before feeding the machine | |||
| Bucket is submerged in the clay before startin | "Open the discharge plug under the bucket assembly, remove the material inside the bucket tank, replace the coupling. Advise the operator to follow the Start/Stop Sequence" | |||
| Foreign Material present in the feed | Foreign material such as crow bars, tmt bars or anything that can block the rotation of the bucket can break the coupling. Identify and remove. | |||
| 2 | D-20 | Gearbox Faiure | Lubrication oil is low / empty | Top up oil periodically till the level tube. |
| Leakage of oil from the shaft | Change the oil seal. If leakage continues, contact the head office. | |||
| Bucket is submerged in the clay before startin | "Open the discharge plug under the bucket assembly, remove the material inside the bucket tank, replace the coupling. Advise the operator to follow the Start/Stop Sequence" | |||
| Load is very high | Reduce the load | |||
| 3 | D-21 | Water does not drain through the buckets | Blinding of the Bucket Mesh | Clean the blinded meshes on the buckets |
| Water is too High | Reduce the inlet water | |||
| Bucket RPM is high | Use a VFD to reduce the speed of the bucket.The output speed must be in the range of 3.5 to 4.5 RPM | |||
| 4 | D-22 | Pillowblock bearing Failure | Insufficient Lubrication | Change the pillow block and advise the operator to lubricate the bearings periodically |
| Bearings corroded due to excessive water | "Change the pillow block Check if the grease used is water resistant. Lithium / Lithium complex greases have little resistance to water and may fail soon. Advice the operator to use a Water Resistant Grease." | |||
| 5 | D-23 | Hydrocyclone underflow distributor box wear | This wear is normal and acceptable | Weld the worn out area if possible, else Replace the damaged part. |
| 6 | D-24 | M - Sand is course | Bucket Mesh Worn Out | Replace the bucket meshes |
| Bucket Mesh size is large | Replace with small aperture size | |||
| Finer Material reporting to the Hydrocyclone | Open the distributor box on the M-Sand Side to enable finer materials to fall into the M-Sand | |||
| Feed size is small | Check the feed size, if the feed size is too small relative to the size of the apertures on the M-sand side, change the PU-Panels for correct apperture. | |||
| Feeding is low | Increase the feed | |||
| Nature of raw material. | Contact a Senior Officer for support |
| S. No | Code | Fault | Cause | Corrective Action |
|---|---|---|---|---|
| 1 | D-01 | Abnormal Vibration in Dewatering Screen | Direction of vibromotor are incorrect. | "Ensure that the vibromotors run at opposite direction relative to each other. The vibromotor present towards the output of the screen shall rotate towards the direction of flow of the material whereas the other motor shall rotate in the opposite direction." |
| Cam setting is improper. | Make sure that all cams are adjusted to the same angle and orientation. If not, match everything. | |||
| Vibromotors are running at Asynchronous Speed. | Ensure that the motors are terminated properly. Loose connection may lead to loss in the speed of the motor. | |||
| Any one of the vibromotor may not be running | "Check if the contactor of the motor has tripped. Check for fuse blow out Check for coil burn out in the vibromotor Check if the shaft has seized into the bearings (Bearing Failure)" | |||
| The mounting bolts of the vibromotors are loose | Tighten the fasteners to the appropriate torque. Use a torque wrench if possible. | |||
| The fasteners of the pipe flange may have gone loose | Tighten the fasteners to the appropriate torque. Use a torque wrench if possible. | |||
| The fasteners that affix the deck to the main frame may have gone loose | Tighten the fasteners to the appropriate torque. Use a torque wrench if possible. | |||
| The dewatering screen is not properly seated. | "Check for bends in the Fabricated Rubber Springs (FRS). If the dewatering is not properly seated onto the FRS, make them straight by lifting the screen above and assembling it back to the correct FRS position." | |||
| Voltage Drop | Check power Supply | |||
| Broken Suspension Parts | Check the Fabricated Rubber Springs (FRS) for damages | |||
| Screen Operating near the natural frequency of the supporting structure | Install brace on the support | |||
| Screen operating at or near critical speed | Consult the design department and change the speed. DO NOT RUN THE MACHINE FURTHER | |||
| 2 | D-02 | Dewatering Deck frame crack | Abnormal Vibration | Refer D-01 |
| External members such as the output chute or other structural member may be touching the screen body that may arrest the vibration and cause cracking | Remove anything that may arrest the free vibration of the screen | |||
| Field modification by user such as welding and cutting that may lead to abnormal stress | Recommend to replace the deck. | |||
| Load too high | Reduce the load | |||
| Deck worn out | Recommend to replace the deck. | |||
| 3 | D-03 | Presence of fines in M- Sand | Input Fresh Water is Low and Classification is not proper | Increase the flow rate / capacity of the fresh water pump. |
| Introduce Sprinklers to remove the fines. | ||||
| Input Feed is High | Reduce the feed | |||
| 4 | D-04 | M-Sand is too coarse | Feed size is small | Check the feed size, if the feed size is too small relative to the size of the apertures on the M-sand side, change the PU-Panels for correct apperture. |
| Feeding is low | Increase the feed | |||
| Nature of raw material. | Contact a Senior Officer for support | |||
| 5 | D-05 | Presence of fines in P - Sand | Pressure of hydrocyclone is too low | Refer D-07 |
| Apex size is large | Change the apex to smaller size (Size recommended by our Engineer) | |||
| Vortex Finder size is small | Increase the Vortex finder size ( Size recommanded by our Engineer) | |||
| Roping in Hydrocyclone | "Roping is caused when the apex capacity is exceeded. This will collapse the air core inside the hydrocyclone and the output will look like a rope. Increase the size of the apex and make sure that required pressure is delivered by the pump." | |||
| No coarse material in the feed | Make the input to the hydrocyclone more coarse. | |||
| Change in sludge concentration on slurry tank | Reduce the feed and increase the water | |||
| 6 | D-06 | Discharge of P Sand into the sludge | Hydrocyclone Operating pressure is too low | Refer D-07 |
| Apex diameter is small | Increase the apex size (Size recommanded by our Engineer) | |||
| Vortex Finder diameter is Large | Reduce the vortex finder size (Size recommanded by our Engineer) | |||
| 7 | D-07 | Pressure of hydrocyclone is too low | Increase the pump speed | "Increase the pump speed by changing the pulley (Recommended to set 1.24 Bar for proper classification) While increasing the pump speed keep an eye on the motor current consumption, as speed is directly proportional to current and the motor may trip or overheat. If you are not able to achieve the required pressure with the current motor, select the immediate next higher capacity motor. But also make sure that the bigger motor can be mounted on the slurry pump." |
| Worn out of Impeller / Inner Casing | Change the Impeller / Inner Casing | |||
| Leakage in suction/discharge of slurry pump and pipe lines | "If the flanges are leaking, seal them by installing a gasket If the suction or delivery pipes have worn out, seal it by welding or changing a new pipe If there is a leakage in the pump, contact the head-office / pump manufacturer If there is a leakage in the slurry hose, add additional hose clamps, or change the slurry hose if it has worn out. | |||
| Belt slippage on slurry pump | Change the Belts | |||
| 8 | D-08 | Jam on slurry pump | Feeding is high | Reduce the feed / Change the slurry pump after relevant discussions. |
| Inadequate water | Add more water | |||
| Improper Start/Stop sequence | Start and stop the machine as per our Engineer suggestion | |||
| Belt slippage on slurry pump | Change the belts | |||
| Motor Speed is very low | Increase the speed | |||
| 9 | D-09 | Flooding on Dewatering | Water is too High | Reduce the inlet water/ sprinkler water |
| Dewatering Vibration is too low | Change the cam in order to increase the vibration | |||
| Inappropiate PU Panel sizes | Change PU Panel size suggested by our Engineer | |||
| Water is not draining down | Create damming effect on the screen deck by introducing artificial dams across the width of the screen. An angle may be welded across the flow for the material to stagnate and allowing more time for the water to drain. | |||
| Slurry Pump speed is low | Ensure that the belt tension is good and the pulley are in good condition and not worn out. | |||
| 10 | D-10 | Wornout on Pipes, Hose and Elbow | Worn out due to natural wear | Recommended to change the pipe and elbow |
| Feed is highly abrasive than expected | Change the Pipes and Elbow to accommodate high abrasive feed | |||
| 11 | D-11 | No overflow on hydrocyclone | Leakage in slurry Pump | "Check the suction and delivery flanges of slurry pump for leakage, if no leakage can be detected, dismantle the suction and delivery pipes from the slurry pump, isolate the pump and check for internal leakages. If Leakage persists, contact the head-office or senior service engineer." |
| Slurry Pump speed is low | Ensure belt slippage/ VFD Starter | |||
| 12 | D-12 | Vibration on the Platform and staircase | Vibration isolation is not proper | Check if the vibration of the dewatering screen is transmitted to the slurry tank by placing a hand over the tank and observing. If Yes, this may be due to faulty Fabricated Rubber Springs (FRS). Change the FRS to arrest vibration. |
| The staircase is not properly supported at the bottom and is hanging | Support the hanging staircase. | |||
| 13 | D-13 | Leakange on the Slurry pump | Due to worn out of gland bush/rope | Change the gland bush/rope |
| 14 | D-14 | Abnormal noise in slurry tank while machine running (air getting sucked nice) | Cavitation on Slurry pump | Adjust the Ball valve/ increase the fresh water in-order to top up the slurry tank and maintain the level of the slurry tank |
| 15 | D-15 | Material travels diagonally across the screen | Vibromotor Failure | Change the vibromotors |
| Damaged Suspension | Repair Suspension | |||
| Screen Out of Level (Side to Side) | Level Screen | |||
| Machine racking or off motion | Refer D-16 | |||
| Unevenly balanced vibrator Weights | Match Weights | |||
| 16 | D-16 | Machine racking | Loose body Components or Bolts | Retighten all body fasteners |
| Damaged Suspension | Repair Suspension | |||
| Broken or damaged structural members, broken welds | Replace the broken members. Do not weld it | |||
| Operating at or near critical speed | Consult the design department and change the speed. DO NOT RUN THE MACHINE FURTHER | |||
| 17 | D-17 | Fatigue Failure of Screen Body | Field modification by user such as welding and cutting that may lead to abnormal stress | Include design requirement in initial specification. Replace failed components |
| Corrosion and Wear | Replace damaged parts | |||
| Screen operating out of Balance | Restore Balance | |||
| Operating at or near critical speed | Consult the design department and change the speed. DO NOT RUN THE MACHINE FURTHER | |||
| External members such as the output chute or other structural member may be touching the screen body that may arrest the vibration and cause cracking | Remove anything that may arrest the free vibration of the screen | |||
| Excessive Feed Rate | Reduce the feed | |||
| 18 | D-18 | Material travels in wrong direction | Screen running in wrong direction | Reverse Motor direction |
| Both the vibromotors are running in the same direction | "Adjust the motors to run at opposite direction to each other. | |||
| 19 | D-19 | Hydrocyclone underflow water is high | Pump speed is low | Increase the speed of the pump |
| Pressure drop in the piping circuit | Arrest the leakages. | |||
| Solids in the slurry tank is low | Increase the feed or reduce the water in the slurry tank | |||
| 20 | D-20 | Belt Slippage in Slurry Pump | Irregular pumping | "Check the slurry for irregular concentration. Make sure that the slurry is thoroughly mixed and of uniform concentration" |
| Slurry Pump Jam | Refer D-08 |
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