refinador beloit
TRANSCRIPT
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Installation, Operation and Maintenance ManualDD3000 Refiner
GL&V USA Inc. 141 Burke Street Nashua, New Hampshire 03061 Telephone: 603-882-2711 Fax: 603-595-0035
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Customer Information
Customer: Customer Name goes here
Location: Customer location goes here
Serial Nos.: enter the serial number here
S.O. No.: The S.O. number goes here
Account No.: Enter the Account number here
DRAWING LIST
Drawing 1 goes here
Drawing 2 goes here
Drawing 3 goes here
Drawing 4 goes here
VENDOR DATA
Vendor data goes here
Vendor data goes here
Vendor data goes here
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Preface
This instruction manual provides installation
and maintenance information for the equip-
ment supplied by GL&V Inc. Illustrations
used are typical and are intended to show
the principal design features. The specific
drawings supplied for the unit should be
consulted for more accurate detail. There is
no intent to state or imply any warranties or
guarantees of process or performance. Any
contractual obligations of GL&V are stated
in the terms of the Sales Agreement.
The contents of this manual should be
studied carefully by all Engineering, Su-
pervisory, Operation and Maintenance
personnel before any attempt is made to
install, operate or maintain the equipment.
Although every effort has been made to
provide comprehensive instructions, this
manual may not provide for every contin-
gency which may arise during installation,
operation and maintenance. Should fur-
ther information be desired, or should you
have questions, contact GL&V USA Inc.,
Nashua, NH, U.S.A., Customer Support
Group, telephone 603-882-2711, fax 603-
595-0035. Please be sure to include the
specific serial number of the machine in-
volved when making informational inquiries
or requests for spare parts.
GL&V can provide field service if mills re-
quire support for installation, mechanical
checking or maintenance/repair service. For
further details contact the Customer Sup-
port Group at the numbers listed previously.
WARNINGDo not attempt to install, operate or
perform any work on this equipment
until you have read and fully understoodthe instructions in this manual. Serious
injury can result.
Preface
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Table of Contents
PREFACE 5
SAFETY INFORMATION 11
SAFETY FIRST .......................................................................................................................................12
RECOGNIZE SAFETY INFORMATION ...................................................................................................12
UNDERSTAND SIGNAL WORDS ...........................................................................................................12
SAFETY WARNINGS AND PRECAUTIONS ...........................................................................................13
REFINING PROCESS SCHEMATIC .......................................................................................................19
DECAL LOCATIONS ...............................................................................................................................20
DESCRIPTION 23
GENERAL MACHINE DESCRIPTION ....................................................................................................24
PRINCIPLE OF OPERATION ..................................................................................................................24
DESCRIPTION OF COMPONENTS .......................................................................................................25
Base ..................................................................................................................................................25
Adjusting Mechanism ........................................................................................................................26Bearing and Rotating Assembly ........................................................................................................26
Packing Assembly .............................................................................................................................27
Rotor .................................................................................................................................................28
Electrical Components ......................................................................................................................28
Controls .............................................................................................................................................28
TYPE OF INSTALLATION .......................................................................................................................28
ADDITIONAL COMPONENT INFORMATION .........................................................................................29
Synchronous Motor Torque Data ......................................................................................................29
Motor Data ........................................................................................................................................29
Sliding Head Movement & Old Style Gearmotor Information ............................................................29
Sliding Head Movement & XL Gearmotor Information ......................................................................30
WEIGHTS AND LIFTING 31
MAJOR ASSEMBLY AND COMPONENT WEIGHTS ..........................................................................32
LIFTING ..................................................................................................................................................33
Lifting the Entire Machine ................................................................................................................33
Lifting the Disks and Rotating Head .................................................................................................34
Lifting the Rotating Assembly ............................................................................................................34
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RECEIVING AND STORAGE 35
SHIPPING PREPARATIONS ...................................................................................................................36
LONG TERM STORAGE PREPARATIONS AND CONDITIONS ............................................................36
STORAGE MAINTENANCE ....................................................................................................................37
Every Three Months ..........................................................................................................................37
Every Two Years ................................................................................................................................37
VENDOR SUPPLIED DRIVES AND OTHER EQUIPMENT ..................................................................37
INSTALLATION 39
FOUNDATION AND LEVELING ..............................................................................................................40
Installing the Refiner to the Foundation without a Sole Plate ..........................................................40
Installing the Refiner to the Foundation with a Sole Plate (Optional) ..............................................40
MOUNTING .............................................................................................................................................41
INSTALLATION OF COUPLING ..............................................................................................................41
SETTING DRIVE .....................................................................................................................................42
PIPING AND WIRING .............................................................................................................................43
Piping Installation ..............................................................................................................................43
Mono-Flow Piping .............................................................................................................................43
Two-Pipe Duo-Flo Piping...................................................................................................................44
Packing Box Piping ...........................................................................................................................44
Transmitter Signal Lines ....................................................................................................................45
Electrical Wiring ................................................................................................................................45
MODELS WITH AIR LOCK (OPTIONAL) ................................................................................................45
OIL CIRCULATION SYSTEM (OPTIONAL) ............................................................................................46
Description ........................................................................................................................................46
Installation .........................................................................................................................................47
OPERATION 49
PRE-STARTUP CHECK ..........................................................................................................................50
STARTUP AND OPERATION (TYPE 2) REFINER LOADING STATION ................................................50
SHUTDOWN ...........................................................................................................................................51
CONTROLS .............................................................................................................................................51
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MAINTENANCE 53
GENERAL ...............................................................................................................................................54
LUBRICATION .........................................................................................................................................54
Bearings ............................................................................................................................................54
Recommended Lubricants: ...............................................................................................................54
Adjusting Mechanism ........................................................................................................................55
Recommended Lubricant ..................................................................................................................55
Pressure Fittings At Keyways ............................................................................................................55
Recommended Lubricant ..................................................................................................................55
Coupling ............................................................................................................................................55
Recommended Lubricant ..................................................................................................................55
Gearmotor .........................................................................................................................................56
Circulating Oil System .......................................................................................................................56
Oil cleanliness ...................................................................................................................................56
TROUBLE SHOOTING ............................................................................................................................57
DISMANTLING AND REASSEMBLY OF MACHINE ...............................................................................58
Disk Replacement .............................................................................................................................58
Segmental Disks ...............................................................................................................................58
Segmental Disk Removal ..................................................................................................................58
Segmental Disk Installation ..............................................................................................................59
Adjusting Mechanism .......................................................................................................................59
One-Piece Disks ...............................................................................................................................60
DISASSEMBLY OF ROTATING AND PACKING ASSEMBLY ..................................................................63
Refiners with Coupled Motors ...........................................................................................................63
DISASSEMBLY OF ROTATING AND PACKING ASSEMBLY ..................................................................64
Refiners with Integral Motors ............................................................................................................64
DISASSEMBLY OF INTEGRAL MOTOR AND STATOR .........................................................................64
DISASSEMBLY OF ROTOR COUPLED UNITS ......................................................................................64
REMOVAL OF INBOARD BEARING .......................................................................................................65
34 and 42 inch model refiners with coupled and integral motors ......................................................65
REMOVAL OF OUTBOARD BEARING ...................................................................................................66
34 and 42 inch model refiners with coupled motors ..........................................................................66
REMOVAL OF INBOARD AND OUTBOARD BEARINGS .......................................................................66
For 20 and 26 inch model refiners ....................................................................................................66
REMOVAL OF INBOARD AND OUTBOARD BEARINGS .......................................................................67
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54 inch model refiner ........................................................................................................................67
INBOARD AND OUTBOARD BEARING REASSEMBLY ........................................................................67
All refiners .........................................................................................................................................67
REMOVAL AND REPLACEMENT OF PACKING SLEEVE .....................................................................68
Cleaning ............................................................................................................................................68
Assembly of Packing Sleeve .............................................................................................................68
GENERAL INFORMATION ON LOCTITE ...............................................................................................69
CURING: .................................................................................................................................................69
PACKING BOX ASSEMBLY .....................................................................................................................70
SHEAR PIN REPLACEMENT .................................................................................................................70
SIER-BATH COUPLING INFO ................................................................................................................70
GOOD PACKING PRACTICES FOR ROTATING SHAFTS .....................................................................71
Compression Packing Installation And Maintenance ........................................................................71
SLEEVE INSTALLATION USING LOCTITE RETAINING COMPOUND ..................................................73
APPENDIX 75
SUGGESTIONS FOR THE CARE AND USE OF STAINLESS STEEL EQUIPMENT ............................76
Introduction .......................................................................................................................................76
Precautions .......................................................................................................................................76
Cleaning Procedure ..........................................................................................................................77
RECOMMENDED TIGHTENING TORQUE FOR CAP SCREWS (INCH)...............................................78
RECOMMENDED TIGHTENING TORQUE FOR CAP SCREWS (METRIC)..........................................79
PROCEDURE FOR APPLYING POLYESTER SIGNS ............................................................................80
SPARE PARTS 81
DRAWINGS 83
VENDOR DATA 85
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Safety InformationThe safety labels shown in this manual and on the equipment are for
personnel protection. Replacement safety labels can be obtained at no cost
by contacting the Customer Support Group at:
GL&V USA Inc.141 Burke Street
Nashua, NH 03061
Telephone: 603-882-2711
Fax: 603-595-0035
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Safety Information
DANGER
WARNING
CAUTION
SAFETY FIRST
Safety is the primary concern for the pro-
tection of both personnel and the equipment.
All personnel must thoroughly understand all
safety precautions before operating or doing
any maintenance work on this equipment.
RECOGNIZE SAFETY INFORMATION
This is the safetyalert symbol.
When you see this symbol on your
equipment or in the manual, be
alert to the potential for personal
injury. Be sure to follow all recommended pre-
cautions and safe operating practices.
UNDERSTAND SIGNAL WORDS
A signal word DANGER, WARNING, or
CAUTION is used with the safety alert
symbol. All personnel must understand the
DANGER, WARNING, CAUTION andNOTICE
used throughout the text of this manual, and
on the safety labels located on the equipment.
Danger indicates an imminently haz-
ardous situation which, if not avoided,
will result in death or serious injury.
Warning indicates a potentially haz-
ardous situation which, if not avoided,
could result in death or serious injury.
Caution indicates a potentially haz-
ardous situation which, if not avoided,
may result in minor or moderate injury.
Caution used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, may re-sult in property damage.
Notice is used to notify people of installation,
operation, or maintenance information which
is important but not hazard related.
DANGER
WARNING
CAUTION
NOTICECAUTION
CAUTION
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Safety Information
The following safety precautions and all
mill safety procedures must be observed
during the installation, operation andmaintenance of this equipment to prevent
injury to personnel or damage to
equipment.
PS00091 Rev. A
Failure to follow these instructionscan cause severe injury or death.
Read Operation and Maintenancemanuals supplied with this equipmentbefore operating and servicing.
Follow all mill safety proceduresduring operation and servicing of thisequipment.
WARNING
1. The operator or millwright should use
common sense and good working
practice while operating and main-
taining this equipment.
2. Servicing and maintenance should
be done by qualified personnel, ad-
equately trained and equipped with
the proper tools.
WARNING 3. Do not remove guards prior to or
during operation of machine.
Contact with rotating equipment
can cause severe injury or death.
Listed below are areas that have been
guarded, accompanied by the asso-
ciated warning.
Main Drive Coupling
Rotating coupling.Can cause severe injury.
Do not operate with guardremoved.
PS00121 Rev. A
WARNING
SAFETY WARNINGS AND PRECAUTIONS
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WARNING
4. Do not operate this machine
at pressures exceeding 690 kPa
(100 psig). Overpressurizing the
refiner can cause sudden rupture
of the refiner casing. This can result
in serious injury or death. A refiner
can become overpressurized due
to several factors.
Incorrect refiner application,
Incorrect process control,
Closed or plugged stock lines,
Unusual process conditions.
WARNING
5. Do not operate this machinewithout all of the safety interlocks
in place. These interlocks are
designed to alert the operator
about the low flow and high
pressure conditions that
lead to overpressurization.
Overpressurization can cause
sudden rupture of the refiner
casing. This can result in serious
injury or death.
WARNING
6. Do not work on, climb on or enter
this machine until the following
procedures have been performed.Severe injury or death can result
if these minimum precautions are
not followed.
a. Follow mill Lockout/Tagout pro-
cedures prior to servicing this
machine.
b. Mechanically disconnect the mo-
tor from the driven components
before working on this machine.
c. Isolate the machine from the
process. Close, lock and tag all
valves on all inlet and discharge
lines.
d. Completely drain the machine.
Allow it to cool down to room tem-
perature before performing any
work on it. Hot pulp and liquor can
cause severe burns.
e. Use caution when removing any
access covers. Gaskets maystick, retaining hot pulp or liquor.
f. Completely wash all stock and
liquor off the machine before start-
ing any work on the machine.
PS09591
WARNINGMaximum operating pressure is 100 psi(690 kPa).
Over pressurizing can cause suddenrupture, severe injury or death.
Operate refiner below 100 psi and with alldoor bolts installed. Leave area if warningsignals start.
SAFETY WARNINGS AND PRECAUTIONS(CONT.)
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Safety Information
b. When Stock Pressure (Inlet
or Outlet) Reaches 620 kPa
(90 PSI)
Actuate the gear motor in fast
open mode to completely open
the refiner plates, i.e. to com-
pletely unload the refiner motor.
c. When Stock Pressure (Inlet or
Outlet) Reaches or Exceeds
690 kPa (100 PSI)
If, after execution of 2b the re-
finer pressure (inlet or outlet)
continues to increase to 690 kPa
(100 PSI):
Shut down the refiner drive motor.
Give an audio/visual signal near
the refiner and at the control
room to indicate this condition.
d. Stock Pressure Measuring
Equipment
Reliable stock pressure measur-
ing equipment (pneumatic or
electronic) must be installed and
properly maintained in the stockpipe line immediately before (in-
let) and after (outlet) the refiner,
with a measuring range of 0 to
860 kPa (0 to 125 PSI).
e. Pneumatic Stock Pressure Mea-
suring Equipment
The pressure measuring range
of pneumatic stock pressure
measuring equipment is limited
by the mill instrument air supply
pressure.
If the instrument air supply pres-
sure at the refiner location is, for
instance, only 550 kPa (80 PSI),then the highest stock pressure
that can be reliably measured
is 515 kPa (75 PSI). In such a
case, the stock pressure values
given under 2b and 2c must be
reduced accordingly.
EXAMPLE:
For instrument air supply at the
refiner of 550 kPa (80 PSI):
When stock pressure (inlet or out-
let) reaches 450 kPa (65 PSI):
Actuate gear motor in fast open
mode to completely open the
refiner plates, i.e. to completely
unload the refiner drive motor.
Give an audio/visual signal to
indicate this condition.
When stock pressure (inlet or out-
let) reaches or exceeds 515 kPa
(75 PSI):
Shut down the refiner drive motor.
Give an audiovisual signal near
the refiner and at the control
room to indicate this condition.
SAFETY WARNINGS AND PRECAUTIONS(CONT.)
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Safety Information
d. Mechanical Minimum Process
Flow Limit (F1)
If an electronic process flow in-
terlock (3.1) is not feasible, then
a mechanical restriction should
be provided to prevent the, valve
from closing completely while
the refiner is running. Recom-
mended minimum valve opening
is 15 to 20%.
e. Net Specific Refining Energy
Control (NHPD/T or NkWh/T)
The primary purpose of this
function is to provide uniform
refining as the demand for pro-
cess flow F1 changes. It will,
however, also provide additionalsafety to prevent over-pressur-
ization since excessive heat and
resulting pressure buildup can
be avoided for low process flow
(F1) demands.
SAFETY WARNINGS AND PRECAUTIONS(CONT.) Allocate refiner power (HP, kW)
proportionate to fiber flow
(gpm x % Consistency x Con-
stant) or (lpm x % Consistency xConstant).
f. Stock Inlet Pressure Control
(kPa or PSI)
This feature will maintain a con-
stant stock inlet pressure (kPa
or PSI) over the entire process
flow range F, (lpm, gpm). This, in
turn, will prevent the outlet stock
pressure (kPa or PSI) from ris-
ing excessively when refiners
are used in series under low
process flow conditions.
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REFINING PROCESS SCHEMATIC
P PUMPR1, R2 REFINERS
F1 PROCESS FLOW, (GPM, LPM)
F2 RECIRCULATION FLOW, (GPM, LPM)
F3 REFINER FLOW, F3=F1+F2 (GPM, LPM)
FM FLOW TRANSMITTER
CS CONSISTENCY TRANSMITTER
CC CONSISTENCY CONTROL
DIL DILUTION WATERLIC LEVEL CONTROL
FIC REFINER/RECIRCULATION FLOW CONTROL, (GPM, LPM)
PIC INLET PRESSURE CONTROL
NREC NET REFINER ENERGY CONTROL, (NHPD/T, NKWH/T)
P1 STOCK INLET PRESSURE (PSI, kPa)
P2 STOCK OUTLET PRESSURE (PSI, kPa)
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Safety Information
PS0969Z
NOTICE
Use AGMA No. 8 EP premium grade gear oil with
EP additives and viscosity of 2837-3467 SSU at100F. Drain, flush and renew every three (3)months.
PS09591
WARNINGMaximum operating pressure is 100 psi(690 kPa).
Over pressurizing can cause suddenrupture, severe injury or death.
Operate refiner below 100 psi and with alldoor bolts installed. Leave area if warningsignals start.
Hazardous voltage.Can cause severe injury or death.
Disconnect power before servicing.Lockout/Tagout machine.
PS1030Z
WARNING
NOTICE
PS0971Z
Use NLGI #0 premium
grade multi-purpose non-soap grease with EPadditives, for pressurefittings.
PS0970Z
Under 66C (150F) Use AGMA No. 3premium grade rust & oxidation inhibitiveanti-wear oil with viscosity of 417-510
SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .
Over 66C (150F) Same as aboveexcept use AGMA No. 5 gear oil withviscosity of 918-1122 SSU (202-247)at 38C (100F). Drain, flush and renewevery (3) three months.
NOTICE
PS0713Z
Use NLGI no. 2 premiumgrade multi-purpose
lithium-complex, soap-base grease with EPadditives. Removecovers, flush out greaseand renew every six (6)months.
NOTICE
PS0969Z
NOTICE
Use AGMA No.8 EP premium grade gear oil withEP additives and viscosity of 2837-3467 SSU at100F.Drain, flush and renew every three (3)months.
PS09591
WARNINGMaximum operating pressure is 100 psi(690 kPa).
Overpressurizingcancausesuddenrupture,severe injury or death.
Operaterefinerbelow100psiandwithalldoorboltsinstalled.Leaveareaifwarningsignalsstart.
Hazardous voltage.Can cause severe injury or death.
Disconnect power before servicing.Lockout/Tagout machine.
PS1030Z
WARNING
NOTICE
PS0971Z
Use NLGI #0 premiumgrademulti-purposenon-soap grease with EPadditives, for pressurefittings.
PS0970Z
Under66C(150 F)UseAGM ANo.3premiumgraderust&oxi dationinhibi tiv eanti-wear oilwith viscosi tyof 417-510SSU(91-112 CST) at38C(100 F)Drain,flush and renew every ( 3)threemonths .
Over 66C(150F)Sameasaboveexcept useAGMA No.5gearoi lwi thv iscosity of918-1122 SSU (202-247)at38C(100F).Drain,flushandr enewevery (3)three months .
NOTICE
PS0713Z
Use NLGIno.2 premiumgrade multi-purposelithium-complex, soap-base grease with EPadditives.Removecovers, flush out greaseand renew every six (6)months.
NOTICE
NOTICE
PS0971Z
Use NLGI #0 premiumgrademulti-purposenon-soap grease with EP
additives, for pressurefittings.
RE002
4-002
DD 3000 Side View
DECAL LOCATIONS
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Safety Information
DECAL LOCATIONS(CONTINUED)
DD 3000 Coupled End View
PS05542
Rotating shaft.Can cause severe injury.
Stay clear when operating.
WARNING
NOTICE
PS0971Z
Use NLGI #0 premiumgrade multi-purpose non-soap grease with EPadditives, for pressurefittings.
PS0970Z
Under 66C (150F) Use AGMA No. 3premium grade rust & oxidation inhibitive
anti-wear oil with viscosity of 417-510SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .
Over 66C (150F) Same as aboveexcept use AGMA No. 5 gear oil withviscosity of 918-1122 SSU (202-247)at 38C (100F). Drain, flush and renewevery (3) three months.
NOTICE
PS0713Z
Use NLGI no. 2 premiumgrade multi-purposelithium-complex, soap-base grease with EP
additives. Removecovers, flush out greaseand renew every six (6)months.
NOTICEPS05542
Rotatingshaft.Cancausesevereinjury.
Stayclearwhenoperating.
WARNING
PS0970Z
Under 66C (150F) Use AGMA No.3premiumgraderust&oxidationinhibitiveanti-wear oil with viscosity of 417-510
SSU (91-112 CST) at 38C (100F)Drain, flush and renew every (3) threemonths .
Over 66C (150F) Same as aboveexcept use AGMA No.5 gear oil withviscosity of 918-1122 SSU (202-247)at38 C(100F).Drain,flushandrenewevery (3) three months.
NOTICE
NOTICE
PS0971Z
Use NLGI #0 premiumgrademulti-purposenon-soap grease with EPadditives, for pressurefittings.
PS0713Z
Use NLGIno.2 premiumgrade multi-purposelithium-complex, soap-base grease with EPadditives.Removecovers, flush out greaseand renew every six (6)months.
NOTICE
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Description
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Description
GENERAL MACHINE DESCRIPTION
The DD-3000 is a pressurized four-disk
refiner. The recommended minimum oper-
ating pressure is 20 PSI (1.4 kg/cm2). Themaximum operating pressure is 100 PSI
(7.0 kg/cm2). It is a compact, precision built
unit in which two rotating elements and one
of the non-rotating elements move axially to
vary the pressure applied to the stock pass-
ing through the refining areas. The rotating
element is free to locate its own center be-
tween the two stationary elements so the
need for a thrust bearing is eliminated.
The inlet and outlet are smooth transitions
with no sharp corners to build up stock or
plug the passages. Refiners are manufac-
tured of materials to suit specific mill condi-
tions. Standard construction has stainless
steel lining in all areas in contact with stock.
As with the DD-2000 and DD-4000 Series
designs, this unit can be operated either in
Mono-Flo or two-pipe Duo-Flo. In operation,
the free floating rotor and disks are prevent-
ed from contacting either of the non-rotating
disks during start-up by a locking device.
This device is mounted on the rotating as-
sembly and consists of a pair of air-operat-
ed diaphragms for coupled motor assembly
and a single air-operated diaphragm for
integral motor assembly.
Prior to entry of stock into the refiner, the
diaphragms are inflated, positioning the
rotating assembly against a stop. The stop
maintains the rotor in a pre-set neutral posi-
tion between the disks.
PRINCIPLE OF OPERATION
Most refining is carried out using the prin-
ciple of a rotor with bars operating in close
proximity to a starter which also contains
bars. While some amount of useful fiber de-
velopment can be obtained on the flat bar
surface with a relatively large gap between
refining elements, a major portion of the
fiber development takes place at the bar
edges when the bars are in close proximityso that only the fiber film is keeping the re-
fining elements apart.
The patented spoked rotor provides
Duo-Flo operation with only one inlet and
one outlet pipe. Flow is split inside the Re-
finer.
The floating rotor utilizes the basic stock
film principles which keeps a precise rela-
tionship between the rotating and non-ro-
tating disks. In this way, uniformity of fibertreatment is accomplished with a minimum
of power.
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DESCRIPTION OF COMPONENTS
Base
The base contains the refining cavity, the
bearing pedestal, the top outlet, the drainand the support for the adjusting mecha-
nism hinge. Sizes 20" and 26" have inboard
and outboard bearing guides in the base.
Refining Cavity Lining
The refining cavity is protected
with a stainless steel 304L liner as
standard equipment. Stainless steel
316L can be supplied at extra cost.
The lining is machined and fastened
in place.
Top Outlet Cover
A stainless steel top outlet cover is
supplied when the unit is arrangedfor Mono-Flo operation. For two-
pipe Duo-Flo operation, this cover is
omitted and the discharge opening
in sliding head for Mono-Flo opera-
tion is covered.
Drain Cover
A stainless steel, 3" blind flange
cover is furnished with a 2" NPT (2"BSPT Adapter supplied for metric)
in its center for use as a drain con-
nection. This offers the customer
the option of selecting his own type
drain valve.
DD 3000 Refiner
GEARMOTOR
ADJUSTINGMECHANISM
LIMIT SWITCHADJUSTMENT
SLIDINGHEAD
HINGE
INBOARDBEARING
BASE
AIROPERATEDLOCK
COUPLING
OUTBOARDBEARING
SLEEVE
PACKINGBOX
INLET FORMONOFLOOR DUOFLO
REFININGCAVITY
DUOFLOOUTLET
ROTORROTORHUB
MONOFLOOUTLET
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Description
Adjusting Mechanism
The DD-3000 unitizes the adjusting mecha-
nism housing and permits the thrust load tobe transmitted directly to the door. The ba-
sic worm and worm gear is of our standard
design and the worm and adjusting screw
are immersed in oil at all times. The adjust-
ing screw housing is sealed by the use of
O rings and lip-type seals are used on the
worm shaft. A large oil fill pipe plug is lo-
cated above the adjusting screw and a drain
pipe plug is located beneath the worm. An
air vent breather is located high on the gear
case cover.
The sliding head has a stainless steel liner
at the outside diameter which provides
non-corrosive sliding surface for the lip
seals. Four grease lubricated pads, two with
keyways, guide the sliding head in place,with the keys serving as anti-rotation stops.
The sliding head is joined to the adjusting
screw by flange mounting, and the adjust-
ing mechanism housing is hinged to the
Refiner base to facilitate disk inspection and
replacement.
Bearing and Rotating Assembly
The shaft is mounted on double row ta-
pered roller bearings and the bearings have
been designed to provide sufficient axialtravel to permit the use of cast disks and
the thicker machined stainless steel disks.
Sizes 34" and 42" DD-3000 refiners have
inboard and outboard bearings assembled
in separate bearing housings. The rotating
assembly slides (floats) axially on bearing
housings, inside the guide bores. A key in
each bearing housing O.D. prevents it from
rotating.
Sizes 20", 26" and 54" DD-3000 refiners
have a common bearing housing (quill) for
inboard and outboard bearings. The com-
plete rotating assembly slides axially on
quill O.D. A key on outboard end prevents it
from rotating.
A rubber excluder located against the in-
board bearing end cover prevents water,
which seeps from packing box, from enter-
ing the bearing assembly.
DESCRIPTION OF COMPONENTS (CONTINUED)
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Description
Packing Assembly
The water lubricated packing box is located
in the flanged inlet. It must be removedthrough the refining cavity. Adjustment and
DESCRIPTION OF COMPONENTS (CONTINUED) component replacement is accomplished
from the backside of the refining chamber.
See "Good Packing Practices for Rotating
Shafts" in the Maintenance section for ad-ditional information. The packing sleeve on
PACKING WEEP HOLES
TO PRESSURE GAUGE(PACKING INLET BOX)
STUD AND ELASTICSTOP NUT
CLEAR WATER SUPPLY(PACKING WATER INLET)
PACKING GLAND
PACKING BOX
LANTERNRING
PACKING
SET
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Packing Box Assembly
the main shaft is replaceable. See "Sleeve
Installation" in the Maintenance section for
additional information.
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Description
Rotor
There are two designs of rotor and rotor
mounting hub: one for Mono-Flo applicationand one for two-pipe Duo-Flo application.
Electrical Components
Two pressure switches are mounted on
the side of the refiner. One switch receives
its signal from the inlet stockline pressure
transmitter. When stockline pressure drops
below a preset value, the pressure switch
contacts energize the outfast contactors of
the gearmotor starter package. This action
moves the disks out of refining position at
high speed. The other switch receives its sig-
nal from packing gland water piping. When
water pressure is lost, switch energizes an
alarm. Both switches are prewired and termi-
nate in a conduit box on side of refiner.
Controls
There are a variety of controls available
for the DD 3000 Refiner. They range from
manual controls like the "T" series to the
programmable series of PRC controllers.
Contact GL&V for more specific information.
DESCRIPTION OF COMPONENTS (CONTINUED) TYPE OF INSTALLATION
Primary types of installations are Mono-Flo
and two-pipe Duo-Flo. Low stock flow ap-
plications require recirculation from outlet ofrefiner to pump suction.
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Description
ADDITIONAL COMPONENT INFORMATION
Synchronous Motor Torque Data
Percent Starting Pull In Pull Out
Full Load Torque 50 50 150
Motor Data
Model 20" Size 26" Size 34" Size 42" Size 54" Size
WR2Effect 89 lbs. - ft.2 420 lbs. - ft.2 1300 lbs. - ft.2 4000 lbs. - ft.2 10,200 lbs. ft.2
Sliding Head Movement & Old Style Gearmotor Information Motor Output High Low HandModel Motor HP Speed Speed Speed Speed Wheel
Frame RPM RPM in. / min. in. / min. in. / min.
20" 7430RC .5/.08 1620/270 35/5.9 .280 .0472 .008
26" 204RC 1/.166 1620/270 35/5.9 .280 .0472 .008
34" 225RC 1.5/.25 1620/270 11/1.8 .297 .0486 .027
42" 254RC 3/.5 1620/270 22/3.7 .2992 .050 .013654" 254RC 3/.5 1620/270 15/2.5 .30 .050 .020
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Description
Sliding Head Movement & XL Gearmotor Information
Motor Output High Low HandModel Motor HP Speed Speed Speed Speed Wheel
Frame RPM RPM in. / min. in. / min. in. / min.
12" M48WG12F .12 1140 29 - .116 .004
20" T56CG16F .5/.12 1725/450 20/5 .160 .040 .008
26" 204RC 1/.166 1725/450 20/5 .160 .040 .008
34" 225RC 1.5/.25 1750/440 7/1.7 .191 .046 .027
42" 254RC 3/.5 1750/440 11/2.8 .150 .037 .013654" 254RC 3/.5 1750/440 11/2.8 .220 .056 .020
ADDITIONAL COMPONENT INFORMATION
(CONTINUED)
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Weights and Lifting
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Weights and Lifting
MAJOR ASSEMBLY AND COMPONENT
WEIGHTS
Servicing the DD 3000 Refiner may require
the removal of heavy sub-assemblies orcomponents. The weights listed are to be
used to select the proper lifting equipment.
DD 3000 MAJOR COMPONENT WEIGHTS
20 26 34 42 54
lbs kgs lbs kgs lbs kgs lbs kgs lbs kgsComplete Refiner 5,000 2273 6,500 2955 13,500 6136 25,000 11364 40,000 18182
Rotating Assembly 875 398 1,850 841 1,600 727 1,980 900 8,000 3636
Rotating Head w/Disks 300 136 750 341 1,110 505 2,250 1023 3,820 1736
Each Disk 66 30 180 82 200 91 490 223 640 291
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Weights and Lifting
LIFTING
Lifting the Entire Machine
1. The hoisting system required will vary
based on the size of the refiner in-volved. See the Major Assembly and
Component Weights Chart for weight
information about the specific size
refiner being lifted. Weights range
from 2275 kg (5000 lbs) to 18182
kg (40,000 lbs).
2. The accompanying illustration shows
the recommended method for lifting
the entire dry machine. The lift requires
a four hook slign of the proper size.
CAUTION
Do not attach any lifting
equipment to the refiner shaft.
Lifting the refiner by the shaft can
damage the refiner.
Lifting the DD 3000 Refiner
4 HOOK SLING
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Weights and Lifting
Lifting the Rotor
PLATES
HUB
ROTOR
LIFTING BRACKET
COMPLETE ROTOR WITHLIFTING BRACKET
RE0020-008
LIFTING (CONTINUED)
Lifting the Disks and Rotating Head
A special lifting bracket is used to remove
one-piece disks and the rotating head. Abracket can be purchased with each refiner.
Lifting the Rotating Assembly
CAUTIONDo not allow lifting cables or chains to come in
contact with the finished diameter of the shaft.
Use nylon lifting slings or other padded lifting
equipment for lifting the rotating assembly.
Do not allow any lifting equipment to come in
contact with the packing sleeve.
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Receiving and Storage
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Receiving and Storage
Each machine is carefully packed to prevent
damage in transit. When the shipment ar-
rives, carefully inspect each item listed on
the shipping papers to assure that no dam-age or loss has occurred in transit. If loss or
damage is detected, notify the carrier immedi-
ately and file claim with the carrier.
All DD Series Refiners are shipped as a
complete assembly. Several components
are boxed separately. They are to be as-
sembled at the customers facility. These com-
ponents are:
1. The motor half of the coupling.
2. The lifting bracket for the disks and
the rotating head.
3. The controls.
SHIPPING PREPARATIONS
Under ordinary conditions, the normal shipping
preparations below will protect the machine
in storage for three months. For severe con-
ditions or longer periods, see Long Term
Storage Preparations and Conditions.
Prior to shipment the equipment is thoroughly
cleaned and prepared as follows:
1. All exposed machined surfaces arecoated with rust inhibitor.
2. Lubricant compatible rust inhibitors
are used with greases and oils during
assembly and testing. These protect
the bearings, seals and internal sur-
faces of lubricant chambers.
3. All ports and openings are coveredwith plywood or other suitable material
to prevent entry of any foreign mate-
rial.
4. Depending on the method of ship-
ment the equipment may be covered
or not covered during shipment. Pro-
tective shipping covers may consist
of various materials such as poly-
ethylene shrink wrap, polyethylene
sheets, tarpaulins, etc. Note that
these coverings may not be appropri-
ate for long term storage purposes.
LONG TERM STORAGE PREPARATIONS AND
CONDITIONS
1. To permit shaft rotation during storage,
remove any blocking which mightinterfere.
2. Special care must be taken to main-
tain the rust inhibitor coating on ex-
posed machined surfaces. Renew as
necessary using a rust inhibitor (Spec.
S8310 or equivalent).
3. Store the machine in a weather-tightwarehouse. Controlled atmospheric
conditions are preferred. If this is not
possible, the machine must be shel-
tered completely from the weather.
It must be kept out of direct sunlight.
Ultraviolet rays have an adverse af-
fect on seal materials and any polyeth-
ylene covering used.
4. The machine must not be exposed
to extremes in temperature or rapid
changes in temperatures.
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Receiving and Storage
5. The machine should be protected from
foreign material. Polyethylene sheetmaterial should be applied over a
framework that is large enough to
allow free circulation of air around the
machine. It should also allow access
for any necessary maintenance. Any
wood used on the machine or in the
framework, must be kiln dried.
6. If the machine is stored in a closed
container, a desiccant must be pro-
vided to control the humidity inside
the container. The desiccant must be
accessible for periodic renewal.
STORAGE MAINTENANCE
To assure maximum protection during long
term storage, the following maintenance must
be performed.
Every Three Months
1. Rotate the shaft several revolutions
by hand. This will ensure that the
rust inhibitor thoroughly coats the
bearings and internal surfaces.
2. Inspect all exposed external machined
surfaces for integrity of the rust in-hibitor coating. Renew as necessary.
3. Inspect integrity of cover material.
LONG TERM STORAGE PREPARATIONS AND
CONDITIONS (CONTINUED)
Every Two Years
1. Purge all greases and rust inhibitors
from the machine. Renew all lubri-
cants using lubricants specified in theLubrication Sectionof this manual.
2. Renew rust inhibitor coating on all
exposed machined surfaces as speci-
fied previously.
3. Carefully inspect the cover material
and its framework. Replace as nec-
essary.
VENDOR SUPPLIED DRIVES AND OTHER
EQUIPMENT
For special long term storage instructions for
items not made by GL&V, see the vendor
instructions.
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Receiving and Storage
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Installation
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WARNING
Follow all mill lockout/tagout proceduresbefore working on this machine.
Unexpected machine operation can
cause property damage, serious injury
or death. All energy sources including
process piping must be properly locked
out and tagged before any repair work
or maintenance is done. Read and follow
all safety precautions in the Safety
Section of this manual.
FOUNDATION AND LEVELING
The size of the foundation is shown on the
Certified General Arrangement Drawing.
The drawing also shows the size, number
and location of the foundation bolt holes.
Note that the distance from the center of the
outlet port on the casing to the end of the main
motor shaft is critical. Particular care must be
used to ensure that this dimension is correct
when installing the foundations.
The refiner must be leveled to within .26
mm per meter (.003" per foot).
Installing the Refiner to the Foundation
without a Sole Plate
1. Use the machined surface of the
casing outlet as the leveling surface.
2. Build shims under the base at all
anchor bolt locations. Use the mini-
mum number of shims possible.
3. Tighten the nuts on the anchor bolts.
Recheck the refiner for level.
4. Grout under base with non-shrinkgrout. Do not overlap onto the re-
finer base.
WITHOUT SOLE PLATE WITH SOLE PLATE (OPTIONAL)
GROUT
REFINER BASE
SHIMS
ANCHORBOLTS
FOUNDATION
CAP SCREWS
SHIMS
ANCHORBOLTS
FOUNDATION
REFINER BASE
SOLEPLATE
GROUT
RE0020-009
Foundation Requirements
Installing the Refiner to the Foundation
with a Sole Plate (Optional)
Sole plates may be one-piece or multi-piece.
This is determined by the size of the refiner.
1. Use the machined surface of the sole
plate(s) as the leveling surface. If the
sole plate is a multi-piece, the pieces
must also be level to each other.
2. Build shims under the sole plate(s)
at all anchor bolt locations. Use the
minimum number of shims possible.
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3. Tighten the nuts on the anchor bolts.
Recheck the sole plate(s) for level.
4. Grout under the sole plate(s) with
non-shrink grout.
5. Mount the refiner to the sole plate(s)
after the grout has set.
MOUNTING
Prepare Refiner location (use care and
follow foundation dimensions shown onGeneral Arrangement and Installation
Drawings).
Locate Refiner on foundation. Level the Re-
finer with .003 inch (.08 mm) per foot. Use
machined surface of casing outlet as level-
ing pad. Build up shims under base at all
anchor bolts. Use the minimum number of
shims possible.
Tighten nuts on anchor bolts.
Check level in all directions at casing outlet
(machined surface). Level should be within
.003 inch (.08 mm) per foot.
If desired, nuts could be tack welded to an-
chor bolts.
Grout concrete under base; use care not tooverlap onto base of Refiner.
INSTALLATION OF COUPLING
Motor half coupling is supplied by GL&V
and may be mounted by the motor manu-
facturer, by GL&V or in the field in accor-
dance with the following:
1. Insert key on motor shaft.
2. Slide coupling sleeve and O Ring
over shaft.
FOUNDATION AND LEVELING(CONTINUED)
Motor Half Coupling - Type "HM" - "FMS"
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3. Lubricate shaft with anti-gallant.
4. Heat coupling hub in hot oil, oven orwith torch, to approximately 300F
(149C).
CAUTION
If torch is used, be careful and
prevent flame from coming into
contact with hub teeth.
5. Use suitable handling equipment
and install hub onto shaft quickly so
as not to lose its expansion. Take
care when installing to be sure it isin alignment. Hub must be mounted
with teeth away from motor to pro-
vide for part of travel in coupling.
NOTICE
End of coupling hub must be flush
with end of shaft.
SETTING DRIVE
Drive motor should be mounted and leveled
on a separate sole plate. Take particular care
in setting the distance between drive shaft
and Refiner shaft. Refer to General Arrange-
ment Drawing for dimension from center of
casing outlet port to end of motor shaft.
1. With motor set in place with re-
spect to the Refiner, check angular
alignment with dial indicator set on
Refiner coupling hub and read-off
vertical face of motor coupling hub.
Maximum allowance is .002 inch
INSTALLATION OF COUPLING (CONTINUED)
No. 8 Slide Coupling for 54" Refiner
(.05 mm) between readings taken
every 90 degrees.
2. Check offset alignment by settingindicator on O.D. of Refiner coupling
hub and reading off O.D. of motor
hub. Rotate shaft and take readings
90 degrees apart. Relocate motor
on mounts until the angular align-
ment is within .002 inch (.05 mm)
total indicator reading.
3. After motor and coupling are prop-erly aligned, dowel motor to sole
plate. This will facilitate replacement
if for any reason the drive has to be
removed.
NOTICE
Be sure adjusting mechanism is
closed and bolted to base before align-
ing coupling.
4. Make sure coupling flanges are thor-
oughly clean, then insert gaskets and
stop plate.
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5. Secure flanges together with bolts,
lockwashers and nuts.
6. This coupling is oil lubricated. Use pre-
mium quality oil, having a viscosity of
2837-3467 SSU at 100F (38C) and
extreme pressure additive package
containing no lead.
Rotate the coupling until the oil holes
in the Refiner half are at 45 degree
and 225 degree positions. Removeboth plugs. Fill the coupling half with oil
through the upper (45 degree) hole un-
til oil flows out the lower hole. Replace
plugs. Repeat for motor half coupling.
The following table indicates coupling oil
capacities:
Coupling Oil CapacitySize No. (Pints)
3.5 3/4
4 1
4.5 1 1/4
5 1 3/4
5.5 2 3/4
6 3 3/8
7 4 3/4
8 5 1/2
PIPING AND WIRING
Piping Installation
Piping system layout is left to the discretion
of the customer. In cases of either Mono-Flo or Duo-Flo (specified on Certification
Sheet), customers to supply a two inch
flush-out line at the Refiner inlet with neces-
sary gage and check valves. Refiners are
supplied with stockline pressure transmit-
ters which customers install in inlet and out-
let stocklines.
Mono-Flow Piping(Refer to applicable General Arrangement
and Installation Drawing)
It is recommended that the customer install
a stock shut-off valve on the inlet pipe near
the refiner to permit wash-up or bypass.
The inlet stockline pressure transmitter
is installed down stream from the shut-
off valve. Top center opening in refiner is
sealed off.
On the discharge outlet in the sliding head,
customer should install an elbow, a pres-
sure transmitter and then a throttling valve.
Next, a flexible outlet hose, approximately
SETTING DRIVE(CONTINUED)
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60 inches long, should be connected.
Hose must be capable of supporting 150
psi working pressure and 150 F operat-ing temperature. For a higher temperature
refining, the flexible connection should be
selected to withstand 250 F.
Drain connection located at the bottom
center of the refiner is threaded for a two
inch NPT connection. A two inch valve is
recommended to permit adequate refiner
flush-out. Drain installation is left up to thecustomer's discretion.
Two-Pipe Duo-Flo Piping
(Refer to applicable General Piping Ar-
rangement Drawing).
It is recommended that the customer install
a stock shut-off valve on the inlet pipe near
the Refiner to permit wash-up or by-pass.
The inlet stockline pressure transmitter is in-
stalled down stream from the shut-off valve.
Top center opening is the discharge port.
Drain connection located at the bottom
center of the Refiner is threaded for a two
inch NPT connection. A two inch valve is
recommended to permit adequate Refinerflushout. Drain installation is left up to the
customers discretion.
PIPING AND WIRING (CONTINUED) Packing Box Piping
To ensure proper packing box operation,
the mill must regulate fresh filtered water
to the packing box at a rate of 1-1.5 GPM(3.8-15.7 lpm) with a supply pressure of 15
PSI (1.05 kg/cm2) above stock inlet pres-
sure. See illustrations "Packing Box Assem-
PACKING WEEP HOLES
TO PRESSURE GAUGE(PACKING INLET BOX)
STUD AND ELASTICSTOP NUT
CLEAR WATER SUPPLY(PACKING WATER INLET)
PACKING GLAND
PACKING BOX
LANTERNRING
PACKINGSET
RE0024-007FHT
Packing Box Assembly
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bly" and "Packing Box Piping Schematic"
for complete piping arrangements.
PIPING AND WIRING (CONTINUED)
FRESH MILLWATER SUPPLY
VALVE, GUAGE AND OPTIONALFLOW METER BY CUSTOMER
GAUGE, PRESSURE SWITCHAND VALVE BY GL&V
TODRAIN
PACKING BOX
FM
G1
G1 PS-2
V-2
NOTES:
1. Set packing box inlet flow to approximately 1-1.5 gpm (3.8-5.7 lpm) at 15 psi (1.05 kg/cm2) above stock
inlet pressure by adjusting valve V-1.
2. Set packing gland water pressure alarm switch (PS-2) to 3 - 5 psi (0.21-0.35 kg/cm2) below stock inletpressure.
3. Set packing box outet pressure (G-2) to 10 psi (0.7 kg/cm2) above stock inlet pressure by adjustingoutlet needle valve (V-2). Do not close valve completely.
Packing Box Piping Schematic
Transmitter Signal Lines
Connections to stockline transmitters
should be made in accordance with stock-
line pressure system.
Electrical Wiring
All internal refiner wiring is complete and
terminates at the conduit boxes. The bal-
ance of the wiring must be accomplished
in accordance with existing local Electri-
cal Codes and applicable Refiner Control
Manual.
MODELS WITH AIR LOCK (OPTIONAL)
Mill should provide clean, dry air to the
pneumatic cylinder of at least 60 psi (4.2
kg/cm2).
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OIL CIRCULATION SYSTEM (OPTIONAL)
Description
A separately mounted, complete oil lubri-
cation system may be supplied to providelubrication for the bearings on the rotating
shaft of the Refiner.
The lubrication system will contain the fol-
lowing components:
(1) oil reservoir with level gauge, ther-
mometer, filler-breather, drain, dump
strainer and return port.
(1) or (2) Oil pump and motor
(1) oil filter
(1) water cooled heat exchanger
(1) water temperature controller for heat
exchanger
(1) thermometer for oil at heat exchang-
er outlet
(1) pressure gauge
(1) immersion oil heater
(2) flow control needle
valves*
(2) flow switches*
(1) load switch*
* These are included in the
Flow Control Unit mounted
on the Refiner.
The exact specifications of each compo-
nent of the lube system will depend on
the manufacturer. The literature supplied
by the manufacturer with reference to the
maintenance, specifications and service
of the circulation system is located in a
separate manual.
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Installation
The circulating system should be locatedwithin 10 feet of the Refiner, allowing the
most direct routes for the oil feed and return
lines. Once the unit is located, it should be
securely anchored.
An oil feed line supplied by the customer
should be installed between the Flow Con-
trol Unit on the Refiner and the outlet con-
nection on the lube system.
An oil return line (minimum 3/4" (20mm) I.D.)
should be installed between oil outlet on the
Refiner and the oil return port on the circu-
lating system. This return line is supplied by
the customer and may be hose, tubing or
pipe with a minimum slope of 1/2" (13mm)
per foot of run. An oil sight indicator in thisline is helpful but not essential.
The next step is to make the electrical con-
nections. The oil pump and oil immersion
heater should be wired to appropriate pow-
er supplies as indicated on their respective
name plates. The pump rotation should be
checked and must be as indicated by the
arrow on the housing or motor. All electrical
components and wiring other than thosesupplied with the system are the responsi-
bility of the customer.
Once all connections are made, the oil sys-
tem must be checked for operation and per-
formance prior to Refiner start-up. At this
time, the oil reservoir should be filled.
Use AGMA #2 premium grade rust and oxi-dation inhibited anti-wear oil with viscosity
of 284-347 SSU at 100 F. Drain, flush and
renew every three (3) months. Use SHELL
TELLUS #68 oil or equivalent or see Ven-
dor's specs in separate manual, if supplied.
Fill reservoir to level indicated on side of
tank. Turn on the immersion heater and al-
low the oil to warm up to 100F (38C) be-
fore proceeding.
To check the system, it is necessary to dis-
connect the supply lines at the Refiner and
measure the flow rates. When the oil is up
to temperature and the lines are discon-nected, start the pump. Collect the oil in an
appropriate container and measure the flow
rates. At 25 psi (1.8kg/cm2) oil pressure, the
flows should be 1 pint/minute/ bearing (.47
liters/min/bearing).
If a flow is incorrect, adjust the flow control
needle valve and the pressure relief valve
to give the correct oil flow rate at an oilpressure of 25 psig (1.8kg/cm2).
When the proper flow is set, check the flow
and pressure switches for proper operation.
This can be done by checking for continu-
ity across each switch when the flow and
pressure are reduced by slowly opening the
pressure relief valve. Both switches should
open at about 75% of their recommended
set point. The pressure switch may be ad-
justed if it is set improperly; however, the
flow switch has a fixed set point and must
be returned for replacement if it is not oper-
ating properly.
OIL CIRCULATION SYSTEM(OPTIONAL)
(CONTINUED)
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PRE-STARTUP CHECK
Prior to startup, make sure all piping con-
nections are secure and that any electrical
connections are complete and covered.
CAUTIONThe Refiner main shaft bearings are
designed to be used with oil lubrication.
Use of alternative lubrication will void
the warranty.
Do not make any attempt to start Refiner
without checking oil level. Refer to "Lubri-
cation" in the "Maintenance Section" of this
manual for proper lubricants.
NOTICEThe Refiner is shipped with preservative oil.
This must be drained and replaced prior to
Refiner start-up.
Prior to actual Refiner operation, the op-
erator must ascertain that clearance exists
between the disks. Generally, a minimum
of 3/32" (2.4 mm) is set on each side of the
rotor head. To determine proper minimum
clearance, refer to Limit Switch Setting in
Maintenance Section.
Set pressure switches as follows:
Low stockline pressure alarm switch is set
at 10 psi.
Packing gland pressure switch is set at a
valve 20% below stock inlet pressure.
STARTUP AND OPERATION (TYPE 2) REFIN-
ER LOADING STATION
1. Turn on packing box water. Check
to see that water is visible around
the refiner shaft. If it is not, loosen
the elastic stop nuts retaining the
packing gland.
2. Energize control panel.
3. Start main Refiner motor.
4. Adjust packing gland using elastic
stop nuts so water drips from pack-
ing gland but does not sling off re-
finer shaft. Check water pressure
gauge reading, it should be at least
10% below normal operating stock
inlet pressure. If pressure is incor-rect, adjust valve located below
gauge to correct.
NOTICE
Final water flow to packing box
should be 1-1.5 GPM (3.8-5.7 lpm)
5. Open stock outlet valve at least
25%, then open stock inlet valve
and/or start stock pump.
6. Position gearmotor selector switch
on FAST and rotate gearmotor
control IN.
7. Sliding head starts forward at high
speed. Note ammeter or wattmeter
for power level to begin to rise, then
switch gearmotor selector switch to
SLOW speed and adjust final set-
ting to obtain desired power level.
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Operation
8. For refiners piped for Mono-Flo
operation, open or close stock con-trol valve as necessary until outlet
pressure is approximately 2 to 5 psi
lower than inlet pressure (when the
desired power level is reached at
that pressure differential, the refiner
will continue to operate smoothly
provided stock consistency and
through-put rate are maintained
consistently).
CAUTION
Gearmotor will overheat if
allowed to operate more than
thirty minutes.
SHUTDOWN
1. Turn selector switch to UNLOAD.
Alarm light in panel will illuminate
and gearmotor will start in reverse
at high speed.
2. Gearmotor will continue to oper-
ate until sliding head trips the limit
switch which shuts gearmotor off.
3. Shut off stock flow by either closing
inlet valve or stopping pump.
CAUTION
Do not close stock discharge line
valves before stopping the stock
feed pump. It will cause pressurerise in the refining cavity and
may ultimately result in damage
to Refiner (burst) and injury to
personnel.
4. After stock flow stops, flush out Re-
finer by means of the two inch flush-
out line and/or drain valve.
5. Stop the Refiner motor.
CONTROLS
Consult the applicable Control Manuals for
complete information concerning any par-
ticular Refiner control system.
STARTUP AND OPERATION (TYPE 2) REFIN-
ER LOADING STATION(CONTINUED)
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Maintenance
WARNING
Follow all mill lockout/tagout proceduresbefore working on this machine.
Unexpected machine operation can
cause property damage, serious injury
or death. All energy sources including
process piping must be properly locked
out and tagged before any repair work
or maintenance is done. Read and follow
all safety precautions in the Safety
Section of this manual.
GENERAL
Proper maintenance practice will promote
trouble-free operation and ensure better
machine performance.
Care should be exercised during disassembly
to place removed parts in clean, dry and pro-
tected locations. A high quality light oil should
be applied to all parts to prevent corrosion. If
machine is to be left disassembled for a period
of time, openings should be protected to pre-
vent entrance of foreign material.
During reassembly, all new replaced parts
should be checked carefully prior to installation
to ensure that they are proper for that particu-
lar location. Use of proper tools and equipmentfacilitate performance of fine quality work.
LUBRICATION
Bearings
All bearings and gearing require lubrication
at regular intervals.
Main shaft bearings are tapered roller bear-
ings and are lubricated by oil bath.
CAUTIONThe Refiner main shaft bearings are
designed to be used with oil lubrication.
Use of alternative lubrication will void
the warranty.
NOTICERefiner is shipped with a preservative oil.
This must be drained and replaced with
proper oil prior to start-up.
Recommended Lubricants:
1. For operation under 150F (66C)
use AGMA #3 premium grade rust and
oxidation inhibited gear oil with viscos-ity of 417-510 SSU at 100F (38C).
2. Drain, flush and renew oil after ten
days to two weeks of operation; there-
after, every three (3) months or when-
ever there is an indication of sludging.
Use SHELL TELLUS #100 oil or
equivalent.
3. For operation over 150F (66C) use
AGMA #5 premium grade rust and oxi-
dation inhibited gear oil with viscosity
of 918-1122 SSU at 100F (38C).
4. Drain, flush and renew every three (3)
months.
Use SHELL TURBO #220 oil or equiv-
alent.
5. See Oil Circulating System if appli-
cable.
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Maintenance
Adjusting Mechanism
The adjusting mechanism assembly in-
cludes tapered roller bearings, large Acmescrew, worm gear and worm. These are lu-
bricated by oil bath.
Recommended Lubricant
Use AGMA #8 premium grade gear oil
with EP additives and with viscosity of
2837-3467 SSU at 100F (38C).
Drain, flush and renew every three (3) months.
Use SHELL OMALA #680 or equivalent.
Pressure Fittings At Keyways
Sliding head to adjusting mechanism hous-
ing. On new models, the grease fittings are
brought to one central block mounted on
the sliding head. These should be lubricat-
ed every six (6) months.
Recommended Lubricant
Use premium quality multi-purpose
non-soap grease of NLGI No. 0 consistency
with good load carrying ability.
Use SHELL DARINA-EP O or equivalent.
Coupling
Is of the gear type and uses O-Ring seals.The two halves are separated by a steel
plate and each half must be oiled sepa-
rately. Rotate the coupling until the oil holes
in the Refiner half are at 45 degree and 225
degree positions. Remove both plugs. Fill
the coupling half with oil through the upper
(45 degree) hole until oil flows out the lower
(225 degree) hole.
Recommended Lubricant
This coupling is oil lubricated.
Use premium quality oil, having a viscosity
of 2837-3467 SSU at 100F (38C) and ex-
treme pressure additive package containing
no lead.
Drain, flush and renew every three (3)
months.
Use SHELL OMALA-680 or equivalent.
Coupling Oil Capacity
Size No. (Pints)
3.5 3/4
4 1
4.5 1 1/4
5 1 3/4
5.5 2 3/4
6 3 3/8
7 4 3/4
8 5 1/2
LUBRICATION (CONTINUED)
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Maintenance
Gearmotor
Lubrication is extremely important for sat-
isfactory operation. Proper oil level mustbe maintained in the gearcase at all times.
The correct level is indicated by the red
plug. Frequent inspections with the unit not
running (preferably when warm), should be
made by removing this plug to see that the
level is being maintained. If low (without re-
placing oil level plug), add lubricant through
one of the upper openings until it comes
out of the oil level hole. Replace the oil levelplug securely.
Lubricant should be drained and the
gearcase refilled after the first 250 hours
of operation; then every 1500 hours or six
months thereafter, whichever occurs first.
Use only recommended lubricants.
All bearings above the operating oil level
that are provided with a plug, lubricate with
a good grade of ball bearing grease when
changing lubricant.
NOTICE
Do not over lubricate grease packedbearings.
For recommended lubricants, see Man-
ufacturers (Reliance Electric) Instruction
Manual E-3614-8 for master XL gearmotors
in the "Appendix" of this Manual.
Circulating Oil System
See Vendors specs in separate manual.
Oil cleanliness
It is important that the oil be kept clean at
all times.
1. Drain and change oil after first two
(2) weeks of operation. Thereafter,
as indicated.
2. Clean tank carefully once a year
to remove any sludge. Open drain
valve and remove all oil.
3. Replace filter elements (see Specifi-
cation). Clean or replace strainer.
4. Check and clean vent and filler cap
screen. Check and service all other
parts for proper operation (motor,
pump, etc.).
LUBRICATION (CONTINUED)
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Maintenance
TROUBLE SHOOTING
Problem Cause Solution
Bearing overheating Oil level too low or too high. Correct oil level.
Improper oil. Replace with proper lubricant.
Thrust load. Check clearances.
Excessive vibration
Misalignment of coupling. Check alignment.
Bent shaft. Straighten.
Cracked shaft. Replace.
Excessive disk imbalance. Balance disks.
Unusual filling wear Uneven stock consistency. Correct variations of consistency in chest.
Burn through. Raise consistency.
Use less power.
Sliding head wont move, gearmotor runs. Broken shear pin. Replace shear pin.
Sticking sliding head. Lubricate pads, check sliding head seal.
Sliding head wont move, gearmotor wont run. Stock pressure too high. Reduce pressure.
Rotor wont float. Worn packing sleeve. Replace sleeve.
Coupling. Clean and lubricate.
Bearing sticking. Check clearances and adjust.
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Maintenance
DISMANTLING AND REASSEMBLY OF MA-
CHINE
Disk Replacement
Disks are available in one-piece or in seg-ments.
NOTICEWhen installing refining disks, do notuse
an air or electric impact wrench to tighten
to the prescribed maximum torque. The
action of the wrench causes galling onthe threads. However, the impact wrench
may be used to tighten the collar bolts to
an intermediate value (approximately 80
Ft.-Lbs.) (27 KPM), after which the collar
bolts are tightened manually to required
torque value using a hand torque wrench.
See the "Appendix" of this manual for
recommended torque values.
Segmental Disks
Segmental Disks are packed in a box which
contains one set of segments ground to-
gether and should be mounted as a com-
plete disk.
NOTICEIf the disks are match marked in a given
set, they should be assembled in the
proper order per the match marking. Each
segment is marked on the back with the
pattern number designated. Mount this
set of segments in position number as
indicated on instructions included with
shipping material.
Segmental Disk RemovalRemove disk segments from the Refiner as
follows:
1. Place main motor and control panel
electric power switches in the OFF
position and LOCK.
2. Tag switches to prevent personnel
from using.
3. On Mono-Flo piping installation,
disconnect piping from adjusting
mechanism end of Refiner.
4. Remove retaining bolts from ad-
justing mechanism end mounting
flange, then swing open Refiner.
The disk which can be seen boltedto the sliding head is No. 4. The disk
mounted on rotating head is No. 3.
5. Remove No. 4 disk segments by un-
screwing collar bolts. Segments may
be easily carried to an appropriate
location.
6. Remove one segment of the No. 3disk and install the applicable rotor
lifting bracket.
NOTICE
A lifting bracket is recommended
and can be purchased from GL&V.
7. Attach lifting bracket to overhead
sling and take up slack. Unscrew the
eight retaining screws to free the ro-
tating head (containing No. 2 and 3
disks) from the rotating hub.
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Maintenance
NOTICE If rotating head disassembly is
difficult, use two jack screws in
holes in head to facilitate separation.
8. Carefully extract the rotating head
unit from the refiner cavity. Place in
clean location and continue the disk
segment removal.
9. Now the No. 1 disk is accessible and
its segments may be removed.
NOTICE
If disks are to be retained for
future use, clean and inspect all
segments. Keep segments of each
set together, do not intermix. Prior
to storing, be sure to mark their
position identity on them.
Segmental Disk Installation
If the disks to be installed are new (from
GL&V), follow the instruction sheet shipped
with them. For disk identity, refer to Identifi-cation paragraph. If disks have been used
before, identify their proper installation
position from the identity that was marked
on the disks at time of their removal. Care
must be exercised in replacing the disks to
make certain all contact surfaces are clean
and free from burrs.
When replacing the segments, push thesegment radially outward until the two (2)
bosses on the outside diameter of the seg-
ments are seated against the retaining ring.
Then tighten the mounting screws. Torque
to recommended torque values listed in the
"Appendix" of this manual.
Reassemble the rest of the Refiner in re-
verse order of disassembly. Then set ad-
justing mechanism in accordance with the
next paragraph.
Adjusting Mechanism
Setting
NOTICE It is necessary to disengage
gearmotor by moving clutch handle
before rotating handwheel.
1. Rotate handwheel until sliding head
closes up all clearance between
disks. Be sure disks are firmly in
contact.
NOTICE
To ensure disks are in firm contact,
remove center outlet cap or
connection and visually inspect.
DISMANTLING AND REASSEMBLY OF MA-
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Maintenance
2. Adjust the bolts at the air diaphragms
to obtain a clearance of 3/32 of an inch(2.4 mm) between bolts and frame.
This provides a minimum of 3/32 inch
(2.4 mm) disk clearance whenever air
diaphragms are inflated.
3. Now rotate handwheel to back off
sliding head 3/16" (5 mm). Use fol-
lowing table to determine number of
turns required.
4. Set limit switch adjusting rod in ac-
cordance with the paragraph entitled
Setting Limit Switch.
5. After completing limit switch ad-
justment, remove tags and return
switches to normal.
One-Piece Disks
Identification
1. One-piece disks are marked in one
of the following methods:
a. Number consisting of a digit
followed by a dash, then three
more digits. The first digit des-
ignates disk position, the lastthree digits refer to GL&V draw-
ing number.
b. Letter R or S then dash and
three digits. R indicates rotat-
ing disk for positions 2 and 3.
S indicates stationary disk for
positions 1 and 4. Digits refer to
GL&V drawing number. See il-lustration.
DISMANTLING AND REASSEMBLY OF MA-
CHINE (CONTINUED)
#1-STATIONARY DISK
#2-ROTATING DISK
#4-STATIONARY DISK
#3-ROTATING DISK
RE0024-013
Refiner Model 20 26 34 42 54
Sliding Head Movement - Inches .0083 .0083 .027 .0136 .020
(mm) (.20mm) (.20mm) (.70mm) (.35mm) (.52mm)
(Per One Revolution of Wheel
Number of Revolutions required 24 24 7 14 10
to Obtain 3/16" (5 mm) Backout
Clearance
Disc Positions
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Maintenance
One-Piece Disk Removal
1. Repeat steps 1 through 4 in preced-ing paragraph entitled Segmental
Disk Removal.
2. If refiner was piped for Mono-Flo op-
eration, remove rotating head cover.
3. Remove upper two retaining screws
from No. 4 disk (disk inside hinged
housing). Install two threaded 5/8"(16mm) diameter rods about 12"
(305 mm) long into upper two retain-
ing screw holes. For 20" DD Refin-
ers, use 1/2" (12mm) rods.
4. Unscrew rest of retaining screws;
dis