ML20149G240

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Rev 5 to MP 738.1, Traveling Water Screen Overhaul
ML20149G240
Person / Time
Site: Millstone  
Issue date: 07/16/1997
From: Miller R
NORTHEAST NUCLEAR ENERGY CO.
To:
Shared Package
ML20149G222 List:
References
MP-738.1, NUDOCS 9707230072
Download: ML20149G240 (72)
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Text

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.,,,.,,.,7~., x,m.., m m,r,c. z s .-y- .-,.m ..c v TOP' r't HINK' "A 'CT>y EVIEW N t 4% h j &m ;;a; -.p yf8 ,m;dh y.s 9. )y lty sg y ~4g j-8 ,v s 'IYaveling Water Screen Overhaul MP 738.1 Rev. 5 ,m fi 'ws 'h d Approval: .s .m w) PORC Mtg. No: /~ 9/7- /09 Date: /7-/& 97 Effective Date: "l -- \\ 6-97 l 9707230072 970716 I PDR ADOCK 05000245 P PDR l w Level of Use SME: R. Miller General

6; i - e i r.:- l< t t LA Millstone Unit 1 Kj Maintenance Procedure Tiaveling Water Screen Overhaul TABLE OF CONTENTS 1. PURPOSE.....................................................2

2. '

P R E R E Q U I S ITES............................................. 2 1: l 3. P R ECAUTI O N S............................................... 5 4. I N STR U CTI O N S.............................................. 6 4.1 Splash Hcusing Removal................................... 6 4.2 S c re e n Tray Re m ova l...................................... 8 4.3 Spray Pipe Removal...................................... 10 4.4 Drive Chain Re moval.................................... 11 .4.5 S cre e n Ch ain Re m oval................................... 12 [ 4.6 Mo t oge a r Re m oval...................................... 16 . 4.7 Frame Removal and Disassembly........................... 17 4.8 Head Section Disassembly................................ 23 l[ 4.9 Boot Section Disassembly.................. <.............. 26 (U 4.10 Inspection and Repair.................................... 27 4.11. Cleaning and Pain ting.................................... 34 4.12 Boot Section Assembly................................... 35 i 4.13' Head Section Assembly................................... 38 4.14 Frame Assembly and Installation........................... 41 4.15 Scree n Chain Installation................................. 48 4.16 Screen Chain Adjustment................................ 52 l 4.17 Motogear Installation and Alignment....................... 54 J .1 4.18 Drive Chain Installation ~.................................. 57 4.19 Drive Chain Adjustment................................. 59 l 4.20 Lub rica t io n............................................. 60 4.21 -_ Spray Pipe Installation.................................... 63 4.22-Screen Tray Installation................................... 65 l - 4.23 Operational Test......................................... 67 4.24 ' Splash Housing Installation................................ 68 - 5.- R EVI EW AND S I G N - O FF.................................... 70

6. '

R E FER ENCES............................................. 70 ' L (] 7.' SU M M ARY OF CHANGES.................................... 71 - V MP 738.1 Level of Use o STOP THINK ACT REVIEW Rev. 5 General l-lof71 .l

l 1 ~ i i

1.. PURPOSE v

1.1 Objective i The objective of this procedure is to provide maintenance instructions for overhauling Link-Bell Model 45A Traveling Water Screens (commonly l called traveling screen units), Figure 1. f Figure 1 Traveling Screen Unit / 5 ged 8 y pd g y/l%)$ a r R W V- .1.2 Discussion Overhaul involves complete removal and disassembly of the traveling screen unit so that components can be inspected, cleaned, painted, and, if ' necessary, repaired or replaced. The traveling screen unit is then assembled, installed, adjusted, lubricated, and operationally tested. 1.3-Applicability This procedure is applicable to traveling screen units M4-21 A, M4-21B,' M4-21C, M4-21D, and M4-21E.

2. PREREOUISITES 2.1 General

[ 2.1.1 ' An Automated Work Order (AWO) has been prepared and approved as necessary by the Performance Evaluations (PE) Department and Operations Department. (f MP 738.1 Level of Use General ST P THINK ' ACT REVIEW Rev. 5 2 of 71

[-s (~3 2.1.2 Restricted Access Entry Permit in accordance with the lV requirements of WC 4, " Confined Space Entry," has been obtained, as required. l-2.2 ' Documents l, 2.2.1 MP 732.2," Traveling Water Screen Speed Reducer Repair" L - 2.2.2 - MP 771.2,"Smal! AC Electric Motor Repair" 2.2.3 MP 7903," Control of Heavy Loads" 1 2.2.4 MP 791.0 (Att), " Circulating Water (323)" l L y 2.3 Personnel 2.3.1 At least five Maintenance personnel 2.3.2 ' One Operations Job Supervisor 2.3.3 If underwater work is required, at least one Diver 2.3.4 At least one Security Guard q LJ 2.3.5 At least one Chemistry Department representative 2.4 Measuring and Test Equipment 2.4.1 ID micrometer with a range of 2 to 6 inches and minimum ~ accuracy of 0.0005 inch 2.4.2 OD micrometer with a range of 0 to 6-inches and minimum 1 accuracy of 0.0005 inch l i i i \\ p V MP 738.1 Level of Use STOP THINK ACT REVIEW-Rev. 5 1 General 3 0f 71 l l l ~

U j. . O(N 2.5 Tools and Consumables ~ L 2.5.1 Tools i Grease gun l: Alemite #Z-737 grease gun nozzle Mechanic's standard tool kit

  • .. Slings Traveling screen coupling alignment tool

%vo 1% x 12-inch steel support bars Wheel puller .. Four screen chain locking bars . 2.5.2.- Equipment (w. ~~ Hydraulic jack,50-ton capacity minimum %) ' Mobile crane,15-ton lift capacity Modified beam clamp (for chain pin removal or installation) .Gritblasting equipment - 1-ton lifting device 2-ton lifting device .- f. MP 738.1 Level of Use ST P-THINK ACT REVIEW Rev. 5 GeneM 4 of 71

L'" 7 ' - f-2.5.3 Consumables-

Anti-Fouling Woolsley red paint Bitumastic #300 black paint

. K&L Eye-Ease green enamel paint .t L Reduction gear lubricant l ' Rags E i' RTV adhesive 2.5.4 Spare Parts (As Needed) Neoprene rubber material for front splash housing and rear . splash housing gaskets L 2.6 Responsibilities -r 2.6.1 - Unit 1 Operations Job Supervisor oversees all tagging, isolation, c and operation of traveling screen unit during maintenance.- .f i 2.6.2 ~ Diver (s)' perform all undenvater inspections and maintenance as I-directed by Unit 1 Maintenance personnel, q 1 2.6.3 Security personnel guard all Unit 1 Intake Structure access points opened during performance of maintenance. 2.6.4 . Health Facility EMT personnel perform closed volume sampling l l and analysis for authorization of the Restricted Access Entry Permit. I

3. ~ PRECAUTIONS ~~

3.1; Move and handle traveling screen units, and applicable components which meet the heavy load criterion, in accordance with the requirements of- _ MP 790.4, " Control of Heavy Loads." 3.2 Ensure all consumables used in or on plant components are used and L disposed ofin accordance with the requirements of CC 1, " Control of t i' Chemical Consumable Products," and a Restricted Use Permit has been issued as necessary. ,js V Level of Use MP 738.1 r ST P THINK ACT REVIEW Rev.5-General: 5of71 O. --. =.

ilq

4. INSTRUCTIONS l G' l

NOTE 1. Splash housing removal is illustrated in Figure 2. 2. The front side of traveling screen unit is the side facing influent water flow from Long Island Sound. 3. The right-hand side of traveling screen unit is the side to right when facing front of traveling screen unit. 4.1 Splash IIousing Removal Figure 2 Splash Housing Removal SPLASH SE AL PLATE 1 ) [ SIDE PANEL 2 e1 BOLTS @ 7 -y "cS!!!E --J( , TRAY SE AL PLATE - ' ', ' ) i [ ,,, j ' HEAD SECTION SIDE PANEL. ? p INTERMEDIATE SiOE PANEL 7l1jX- ' - g 'j SECTION AA 4 p3 V +^ W \\ - r y h ' < 3.o a, CM) l a ,U.?' _ _ _ _ - - _ __ M _ @E h A ff ?" g g if SHELF \\ GASKET 1 IWc)d bO * ~ ' CHUTE SHELF FASTENE RS F HEX AGON HEAD BOLT 3/8" x 1 1/4" l G HEXAGON HEAD DOLT 5/16" x 11/4" CONCRETE l Mechanic l" 4.1.1 ENSURE traveling screen unit is deenergized. 4.1.2 REMOVE permanent ladder at front splash housing. 4.1.3 REMOVE splash seal plate. F7 4.1.4 RIG 1-ton lifting device to front splash housing. (._/ MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 Ger.eral 6 of 71

=... -. -.. j. [ 4.1.5 REMOVE front splash housing. 4.1.6 - DISCONNECT 1-ton lifting device from front splash housing. 4.1.7 - - R1G 1-ton lifting device to rear splash housing. j l. 4.1.8 . REMOVE rear splash housing. l l 4.1.9 DISCONNECT 1 -ton lifting device from rear splash housing. 4.1.10 - REMOVE and DISPOSE of gaskets for front and rear splash housings. f' 1 -n N) l h MP 738.1 -Level'of Use STOP THINK ACT REVIEW Rev.5 General 7,771

NOTE Screen tray removal is illustrated in Figure 3. l 4.2 Screen Tray Removal 1 Figure 3 Screen Tray Removal FASTENER $ ' O CARRIAGE BOLT 3/4" u 41/2" E LOCKNUT 3/4" f 4 1 d, f i I ~ fl.. ".o. e e j \\\\ D ( =r" ) go O] CHAIN lh. ai fh SEAL PLATE GL EEN Pi ii g / m,.. c .c Tw$ l eg l l : - f# e o O TRAY E I ' o e o 4- / g, ^ t .lbE AL PLATE l Mechanic f 4.2.1 REMOVE coupling guard from head section. MP 738.1 Level of Use STOP THINK ACT REVIEW Rev. 5 GeneGl 8 of 71

o C A UTIO N l L Screen trays must be removed in groups of up to four at crisscross locations around the screen chains in order to equalize weight balance on screen l chains during screen tray removal. ~ \\ l NOTE There are 43 screen trays per traveling screen unit. 4.2.2 REMOVE group of maximum four screen trays from screen chains as follows: Using block and wedge, BLOCK speed reducer input shaft. a. b. Starting with highest screen tray and working down, REMOVE each screen tray of group as follows: 1)' RIG 1-ton lifting device to midpoint of screen tray. r(,q/

2) HOLD seal plates and UNBOLT screen tray from left-hand and right-hand screen chains.
3) REMOVE seal plates.
4) LIFT and MOVE screen tray to storage location.
5) DISCONNECT 1-ton lifting device from screen tray, c.

UNBLOCK speed reducer input shaft by removing block and I wedge. 4.2.3 REQUEST Operations Department jog traveling screen rotation i as necessary to access crisscross locations around screen chains and REPEAT step 4.2.2 until all screen trays have been removed. \\ () Level of Use MP 738.1 STOP THINK ACT REVIEW Rev. 5 General 9gg71

l l l l ( NOTE x_s i l Spray pipe removal is illustrated in Figure 4. 4.3 Spray Pipe Removal l Figure 4 Spray Pipe Removal t STAGGERED NPP SPRAY NOZZLE ',18 ST' 43 5' FASTENERS @ HEXAGON HEAD BOLT 6/8" x 13/4"} [f'^ @ BEVEL WASHER 5/8" ]_ \\ @ HEXAGON HEAD BOLT 1/2" x 1" @ HEXAGON HEAO BOLT 3/8" x 1" 9 \\ i ramen r77- / ORIFICE 4, 4 -SPLASH PLATE 1 A PE 1 U BOLT ' MSEMBLY.. FEEO PIPE y / SPLIT SEAL ' ASSEMBLY [v. 4, !.jg i / q m ?romi S

3. l o

g... _______i_9__

l-------

I BOLTS @ FRONT BRACE = VALVE L FEED PIPE ASSEMBLY BACK BRACE b = l Mechanic f 4.3.1 ENSURE traveling screen unit is deenergized. 4.3.2 REMOVE splash plate from back brace of head section. 4.3.3 IE necessary for spray pipe removal, DISCONNECT screenwash supply pressure indicator and associated conduit from feed pipe. 4.3.4 DISCONNECT piping union between spray pipe and feed pipe. 4.3.5 REMOVE split seal at feed pipe penetration in head section side panel. 4.3.6 DISCONNECT feed pipe from screenwash header. 4.3.7 PULL feed pipe outward through feed pipe penetration in head /] section side panel and REMOVE feed pipe. G ? MP 7381 Level of Use -ACT-REVIEv/ Rev.5 STOP THl$K~ General 10 of 71

4.3.8 UNBOLT spray pipe supports from front brace. ,q 4.3.9 REMOVE spray pipe with attached supports. NOTE Drive chain removal is illustrated in Figure 5. 4.4 Drive Chain Removal l Mechanic l 4.4.1 REMOVE chain guard from head section. 4.4.2 LOOSEN chain tightener moundng bolts. 4.4.3 ROTKfE chain tightener as necessary to obtain maximum slack l in drive chain. j 4.4.4 At chain joint near top of driven sprocket and using modified beam clamp, UNCOUPLE drive chain. 4.4.5 LIFT and REMOVE drive chain from drive sprocket and driven p. sprocket. Lj Figure 5 Drive Chain Removal SPEED REDUCER SPROCKET CHAIN GU ARD /3 7 h>(~4x @M' o. CQ q y \\_ l ] ,, #[ c - ;_ _3 ; i s DRIVEN j saaocket 5 , %g y 9l [k'%_....I O / l c............................= 2..}!! t ggg,clggg-t. = u.........c = = =3.;= y .) \\ J.a \\ \\.\\ ,L .rpL_. + p N. L Level of Use MP 738.1 STOP THINK ACT REVIEW Rev.5 I General l 11 of 71 i^ l

C,a NOTE 1. Screen chain removal is illustrated in Figure 6. 2. As illustrated in Figure 6, each screen chain is removed in three sequential sections; beginning with the rear section, followed by the top section, then the front section. 4.5 Screen Chain Removal Figure 6 Screen Chain Removal 2nd 5ECTION (Top) CAPSTAN NUT JAM NUT F RONT OF ff" SCREEN ~. \\ MT L_ f/ TAKEUP C % s'ts"Ons%'O / {,.? 3E/ [ esU c u 1st 5ECTION (Rear) 3rd SECTION (Frent) n n 5 e wAnn.- g 7. now o I ti [ Mechanic l 4.5.1 RELIEVE drive chain tension. r 4 O) L MP 738.1 Level of Use STOP THINK ACT REVIEW Rev. 5 General 12 of 71 1 t

i a s 1 . r~ t -4.5.2. RELIEVE screen chain tension as follows: L

a.

LOOSEN jam nut on each takeup screw.

b. ' Simultaneously and equally BACK OFF both capstan nuts and LOWER head terminal to its lowest position.

4.5.3 From rear of.travehng screen umt and using locking bars, LOCK each screen chain at upper screen sprockets. 4.5.4 From rear of traveling screen unit and using modified beam clamp, UNCOUPLE each screen chain at chain joint near bottom of upper screen sprocket. 4.5.5 BOLT leading and trailing ends of each screen chain at uncoupled - chain joint. 4.5.6 UNLOCK each screen chain by removing locking bars. l 1 Diver -l 4.5.7 REQUEST Operations run traveling screen rotation until pair of bolts in screen chains become near top of lower screen sprockets.

1 l Mechanic

-l 4.5.8 ENSURE traveling screen unit is deenergized. 4.5.9 From rear of traveling screen unit and usiag locking bar, LOCK i each screen chain at upper screen sprockets. 4.5.10 From rear of traveling screen unit and using modified beam clamp, UNCOUPLE each screen chain at chain joint near bottom of upper screen sprocket. 1 L l b l 7 Ou MP 738.1 Level of Use ~ ACT REVIEW Rev.5 STOP THINK gggggg .13 of 71

._~ C A UTIO N 1. Screen chain can become twisted if handled impro,perly. Do not pick up screen chain by hooking into the center of a coil. Support center of coil as shown below: i s-DO THl3 1_. go w - - WlLW AVOID THl3 2. Do not feed screen chain on its side. Prevent the possibility of twist by feeding screen chain in the manner shown below: DO THIS A avoid THl3 _7 i;-. l l 4.5.11 REMOVE rear section of each screen chain as follows: l a. RIG mobile crane to rear section. l l Diver l b. UNBOLT leading end of rear section. j t l Mechanic l c. UNLOCK screen chain by removing locking bar. d. LIFT and GUIDE rear section out of rear roller track angle. e. DISCONNECT mobile crane from rear section. 4.5.12 Fromfront of traveling screen unit and using locking bar, LOCK each screen chain at upper screen sprockets. /9 .G Level of Use MP 738.1 ST P THINK ACT REVIEW Rev. 5 Gened 14 of 71

~ - _.. .l l Lfs 4.5.13 Frompont of traveling screen unit and using modified beam [:Q clamp, UNCOUPLE each screen chain at chain joint near bottom of upper screen sprocket. 1 1 4.5.14 ' REMOVE top'section of each screen chain as follows: a. RIG mobile crane to top section. b. LIFT and GUIDE top section off of upper screen sprocket. c. DISCONNECT mobile crane from top section, o i 4.5.15 Fromfient of traveling screen unit, REMOVEfront section of i each screen chain as follows: a. RIG mobile cranc tofront section. 1

b.. UNLOCK screen chain by removing locking bar, LIFT and GUIDEfront section around lower screen spro-ket -

c. and out of front roller track angle. d. DISCONNECT mobile crane fromfront section. _-_ O. A._/ l l/s !V Level of Use MP 738.1 ~ gggggy STOP THINK ACT REVIEW Rev.5 15 of 71 i

i l ,f . (J NOTE i l Motogear removal is illustrated in Figure 7. l 4.6 Motogear Removal l Electrician l 4.6.1 OPEN electrical junction box on motor. 4.6.2 CISCONNECT electrical wiring and ground cable from motor. 4.6.3 REMOVE flexible conduit and ground cable from head section. l Mechanic l 4.6.4 REMOVE coupling guard from head section. 4.6.5 RIG 1-ton lifting 6evice to fluid coupling. 4.6.6 DISCONNECT flexible coupling between fluid ~ coupling and motor. j 1 4.6.7 DISCONNECT flexible coupling between fluid coupling and speed reducer. A < Q Figure 7 Motogear Removal FLUlO COUPLING COUPLING GU ARD AtGsD SIDE TO MOTOR FLEXIBLE COUPLING $ PEED REDUCER i MOTORSHAFT I KET CHAIN GUARD fgQ& N=. raw a. =2 TIGH NER

  • " SHIMS se,e y)

-- - - - J. 'k -1 DRIVE PLATFORM g, f. '1 l DRIVEN .. %.SPROCKElT u E f' ,/<g! 3 / ll / I l g.......= -..........: 1...j! j, _,jf.d.,g's y m........ _,,,,,c,,,,,,, .. e g,,4 j y \\ L. jl l \\ l [ s']-,h 4 + n(; v MP 738.1 Level of Use General. STOP THINK ACT REVIEW Rev. 5 t 16 of 71 l r l

1 /7 4.6.8 REMOVE fluid coupling with attached flexible coupling halves. V 4.6.9 ' DISCONNECT 1-ton lifting device from fluid coupling. 4.6.10 RIG 1-ton lifting device to speed reducer. 4.6.11 REMOVE speed reducer from drive platform. ~ 4.6.12 DISCONNECT 1-ton lifting device from speed reducer. 4.6.13 RIG 1-ton lifting device to motor. '4.6.14 REMOVE motor from pad. 4.6.15 DISCONNECT 1-ton lifting device from motor. 4.6.16 COLLECT shims from drive platform and pad. 4.6.17 REMOVE drive sprocket from speed reducer output shaft. C AUTIO N .f3 MP 790.4," Control of Heavy Loads," may apply to components moved and handled in Section 4.7. NOTE Frame removal and disassembly is illustrated in Figures 8 through 11. 4.7 Frame Removal and Disassembly l Mechanic l 4.7.1 UNBOLT boot section from suction well floor. 4.7.2 UNBOLT head section from operating (building) floor. 4.7.3 At head section and using hydraulic jack, JACK entire frame approximately 12 inches off operating floor. ~(v l Level of Use MP 738.1 l General STOP THINK ACT REVIEW Rev. 5 17 of 71 l l

i 4 . t., l l ('~s 4.7.4 ~ RIG mobile crane to head section, t. ) , %.. r Figure 8 - Head Section Removal l FRONT-KNET BRACE BRACE BACK BRACE HE AD SECTION . pggy JACK SCREWS i i 'b b. .3 n. SLOE KNEE PANEL BRACE SUPPORT BARS .f' OPE R ATING '] [

a p

N SECYBON --~ l VARIABLE $1DE VIEW i I I [ U - g l INTERMEDIATE l FASTENERS l SECTION @ HEX AGON HEAD BRACEO -[ i BOLT 5/8" a 11/2" ' k- ]' I @ COUNTERSUNK HEAD 'N BOLT 5/8" x 1 1/2" I,: I q 3 t l l :l i INTE RMEDI ATE l { sECTioN I -l 1 "[ 3 ) BOOT SECTION l d i r 3 i 1 1 g BOTTou oF WELL i 4.7.5 RAISE entire frame until upper pair of holes in side panel guides ) of top variable section are accessible. t i .'a/ MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 General l 18 of 71 L i.

(., 4.7.6 - ' INSERT support bar halfV sy through lower hole of pair in each /q side panel guide of top section variable. g 4.7.7 LOWER entire frame into suction well until support bars in top variable section rest on operating floor. ~ 4.7.8 - REMOVE head section from top variable section as follows: a ' UNBOLT knee braces. ~b. ' UNBOLT back brace, c. . UNBOLT front brace. d. MOVE head section to suitable location for disassembly. 4.7.9 ' DISCONNECT mobile crane from head section. 4.7.10 RIO mobile crane to top variable section. 4.7.11 Slightly RAISE partial frame (top variable section and remaining sections) and WITHDRAW support bars from top variable section. V 4.7.12 RAISE partial frame until upper pair of holes in side panel guides of bmced intermediate section are accessible. .4.7.13 s INSERT support bar halfway through lower hole of pair in each side ~ panel guide of bmced intermediate section.' 4.7.14 LOWER partial frame into suction well until support bars in - bmced intermediate section rest on operating floor. 4.7.15 DISCONNECT mobile crane from top variable section. 4.7.16 DISASSEMBLE tbp variable section from bmced intermediate section as follows:

a. ~ REMOVE cross beams.

. b.1 REMOVE side panels. m e, Level of Use MP 738.1 - General ST P THINK .ACT REVIEW Rev. 5 19 of 71

l ) 1. (~y 4.7.17 COLLECT cross beam shims. l \\r) Figure 9 Diagonal Bracing and Cross Beams Removal R ^ l-DIAGONAL BRACING g i. l CROSS BEAM. FASTENERS @ HEXAGON HE AD BOLT 5/8" x 1 1/2" @ COUNTERSUNK HEAD BOLT 5/8" a 1 1/2" @ HEXACON HEAD BOLT 7/8" x 13/4" GUIDEWAY NEL HIMS. ?bE - h q g !:1'1i i'd$ 4.7.18 RIG mobile crane to braced intermediate section. 4.7.19 Slightly RAISE partial frame and WITHDRAW support bars E,o from braced intermediate section. 4.7.20 RAISE partial frame until upper pair of holes in side panel guides of nonbraced intermediate section are accessible. 4.7.21 INSERT support bar halfway through lower hole of pair in each side panel guide of nonbraced intermediate section. i I s-l\\/ MP 738.1 L Level of Use l . General C'. P THINK ACT REVIEW Rev. 5 20 of 71

U -f w 4.7.22 LOWER partial frame into suction well until support bars in -Q nonbraced intermediate section rest on operating floor. Figure 10 Braced Intermediate Section Removal CROSS BEAM INTERM ATE BRACED DE E e l i -) J [ ] 7 l SUPPORT BAR J '"'hata^" l C 1l 5 , r-- a" E } BOOT SECTION F a.. L. 4.7.23 DISCONNECT mobile crane from braced intermediate section. 4.7.24 DISASSEMBLE braced intermediate section from nonbraced intermediate section as follows: a. REMOVE diagonal braces. b. REMOVE cross beams. c. REMOVE side panels. 4.7.25 COLLECT cross beam shims. 4.7.26 RIG mobile crane to nonbraced intermediate section. 4,7.27 Slightly RAISE partial frame and WITHDRAW support bars -A from nonbraced intermediate section. -( a x-Level of Use MP 738.1 . General STOP THINK ACT REVIEW Rev. 5 21 of 71

.. _... - _.__, _. ~... - s p a. c s.; f 4.7.28 J - RAISE ' partial frame until upper pJr of holes in side panel guides kQ of boot section are ac~ essible. c 4.7.29 : INSERT support bar halfway through lower hole of pair in each - side' panel guide of boot section. ~ i 4.7.30 LOWER partial frame into' suction well until support bars in boot f section rest on operating floor. 3 E . Figure 11 Intermediate Section and Boot Section Removal < s 's CROSS BEAM f 1 I I SIDE

PANEL, INTE RME DI ATE SECTION

,j [ SUPPORT -l BAR,+- a '[ y / [ (OPERATING a l ' l 3 \\ FLOOR 'l [ BOOT SECTION y \\; j' A 'j 'N j U ,) t i .i i -l 4.7.31 DISCONNECT mobile e ane from nonbmced intermediate

section, j

4.7.32 DISASSEMBLE nonbmced intermediate section from boot -section as follows: a. REMOVE cross beams. . b.- REMOVE side panels. ~ 4.7.33 COLLECT cro.cs beam shims. 1 4.7.34 ' RIG mobile crane to boot section. 4.7.35l.. MOVE boot section to suitable location for disassembly. .4;7.36 DISCONNECT mobile crane from boot section. n ' N._)

Level of Use MP 738.1,

.STOP THINK 'ACT REVIEW - Rev. 5 Genemi: 22 of 71 s ~w -+ + w 4 4 e-p 4

4 T I NOTE w/ Head section disassembly is illustrated in Figures 12 and 13. l 4.8 IIcad Section Disassembly Figure 12 Head Section Disassembly LIFTING LUGS i g CAPSTAN NOT WITH ROLLER THRUST BE ARING S g 4 l. M J,. '.~ D' .7 .[IT' 'D [. CHAIN TIGHTENER h4 l} v @2,, " ' MACHIN Efty SUPPORT Y ' n P 8 f , X .,4 i' U Wl' -- lf TAKEUP s SiOE PANEL SCREW Y_a q p OE i FASTENERS I [.'.. W OREASE / T EX I i AND AT F E HEX AGON HE AD BOLT 5/8" n 1%" I d \\ @ HEX AGON HEAD BOLT 5/B'* x 1%" @ HEXAGON HEA0 80LT 3/8"m %" I + COVE R _____-"E AD TERy_ASSEM83__ _, @+ glg-g__-----__--_ 7 7 i g,j e ; 3 I i ) u----- + \\ p MGASKET t r+---SCRE EN SPROCKETS TO BE ---+ .I l CENTRALIZED IN FRAME s 'l l I I / f I l N -.-l FRONT BRACE 'BACK a W g g J R, // = I BRACE ge g g g..- p n,...- .~.- - k f TR AY W10TH PLUS 1'-61/8" JACK SCREW 1 1/8" HOLES l Mechanic l* 4.8.1 REh.OVE takeup bearing housing cover from each side panel. 4.8.2 REMOVE grease pipe from each takeup bearing. 4.8.3 RIG mobile crane to head terminal. 4.8.4 Slightly LIFT to SUPPORT head terminal. 4.8.5 REMOVE bolted channel section from each side panel. 4.8.6 REMOVE jam nut and capstan nut from each takeup screw. l t3 i V MP 738.1 Level of Use ST P THINK ACT REVIEW Rev. 5 Genemi 23 of 71 l I

l gy 4.8.7-REMOVE each takeup screw from head section as follows: Q a. REMOVE stay bolt from takeup bearing and takeup screw. b. UNSCREW takeup screw from takeup bearing. GUIDE takeup screw up through holes in side panel and c. machinery support. 4.8.8 LIFT and MOVE head terminal to suitable location for disassembly. 4.8.9 DISCONNECT mobile crane from head terminal. 4.8.10 DISASSEMBLE head terminal as follows: Figure 13 Head Terminal Disassembly SCREEN SPROCKET 8 FASTENERS. I C E ~ SPR K T q @ SOCKET HE AD CAP SCREW SEGMENT ORNEN l @ LOCKNUT rsPROCKET SEGMENT i TOROUE TUBE I 4 KEY G %J -+ + o {o g. t><3 e "iI TN l l JD , a-TRAY WiOTH PLUS 37;'8" 'r g s HALF HALF SECTION 58 SECTION AA B A4-a. REMOVE takeup bearings and takeup bearing bushings from head shaft.

b. ' UNBOLT driven sprocket segments from right screen sprocket.

c. REMOVE head shaft from torque tube. d. REMOVE key from head shaft. 'l l .A .i ! ( i RJ MP 738.I Level of Use ST P THINK ACT REVIEW Rev. 5 General 24 of 71

k'. t' '4 'l L-y; p,. L - [l.-L A' 4.8.114 ' UNBOLT the' following from side panels: .I ,y l

a. : Machinery support -

,.s ~ b. Back brace L ' c.. Front brace 1 a 4.8.12 - DISPOSE of all fiber-insert locknuts. i 9 i l l i y pv i I i l - l j q i I l ( (. - i N ~ i i t. i MP 738.1

. Level of Use Qggggl: '

STOP THINK ACT REVIEW Rev,5 1 25 0f 71 i ~. .....,.m_._

~* 1 l. l Il NOTE V Boot section disassembly is illustrated in Figure 14. l l 4.9 Boot Section Disassembly 1 igure 14 Boot Section Disassembly 2-SHIM 7 [ BOOT CASTING ~ = SiOE PLATE s "MM f_ _00AL AROUND BOOT l \\ ______4 ]h l Il BOOT PLATE - TRAY WIDTH PLUS 1" MAXIMUM 7/8" MINIMUM ENLARGED SECTION AT AA P-. CROSS BRACE A (HE ADS OUTSIDE) 1 TRAY WIDTH PLUS 3 5/8" Q R,- s > a 4 O d' ! gg SCREEN SPROCKET j 7i g ~ ';k l I s t-{,- i ) k- \\ ~.,- ,/ ] g,' ( l COLLAR r BE ARING ' ( KEY A- .s ~~ ~~'=Y A o E r gyyy 2 E.,' j ,.6 P ').s 1. + SIDE bg i i ( (,,,,f .csg r 2'-2%" R AD, 1/16" -> PLATE a(,, s, s., ) s s l 2*-4" R AD. s(s N p l t i fBOOT / \\ ' k'dh(', ' U C ASTING' \\. i y {-, N BOOT PL ATE w 8h I"

  1. NUM -

(HE ADS OUT SIDE) P TRAY WIDTH PLUS 7/8" MINIMUM + @ A l FASTENERS @' HEXAGON HE AD BOLT 5/8 x 1 1/2" @ COUNTERSUNK HE AD BOLT 5/8" x 11/2" @ SOU ARE HEAD BOLT 3/4" x 21/4" @ WASHER 3/4" @ SQUARE HEAD BOLT 3/4" x 21/4" l Mechanic l 4.9.1 RIG 2-ton lifting device to foot shaft. L 4.9.2 Slightly LIFT to SUPPORT foot shaft. 4.9.3 UNBOLT U-bolts securing bearing halves to each bearing support bracket. n' ( i x"e MP 738.1 L Level of Use STOP THINK ACT REVIEW Rev. 5 l General 26 of 71

1 L,... 4 'h .4.9.4 REMOVE shims from under b'ottom bearing halves. ID L' 4.9.5 RAISE foot shaft out of boot section. L-L^ 4.9.6 . REMOVE bearing halves from foot shaft. l., p 4.9.7 - LOOSEN setscrews on' screen sprockets and collars. ^ - 4.9.8 L Using wheel puller as necessary, REMOVE the following from ~ foot shaft: - a. Screen sprockets

b. ' Collars.

c. Keys 4.9.9. DISCONNECT 2-ton lifting device from foot shaft. a UNBOLT boot plate from boot castings. - 4.9.10 4.9.11 UNBOLT side plates from cross beam and boot castings. pG 4.10 Inspection and Repair l Mechanic -l? 4.10.1 INSPECT boot section, intermudiate sections, and liead section as follows: a. EXAMINE all structural steel for deterioration. 1 b. EXAMINE all side panel flanges and roller track angles for the following: x Straightness l Excessive wear l 1 Deterioration c. EXAMINE all bolts for the following: Tightness Deterioration i ( ,M !~ MP 738.1 Level of Use-GTOP - THINK -ACT ' REVIEW Rev.5 eneral 27 of 71 a

r1 d. EXAMINE boot plate for the following: l K,) Erosion 1 ' Corrosion = L. . Damage 4.10.2 REPAIR or REPLACE boot section, intermediate sections, and head section as necessary. L 4.10.3 INSPECT takeup bearing bushings and head shaft for excessive wear as follows: a. MEASURE outside diameter of each head shaft bearing journal at two locations 90 degrees apart. b. MEASURE inside diameter of each takeup bearing bushing. at two locations 90 degrees apart. c. SUBTRACT head shaft bearing journal measurements from corresponding takeup bearing bushing measurements to obtain takeup bearing clearance, 7_. r i A '# d. TEST takeup bearing bushing does not turn in bearing - housing. 4.10.4 IE takeup bearing clearance is greater than or equal to 0.125 inch OR takeup bearing bushing turns in bearing housing, PERFORM the following: a. REQUEST FLS or Engineering evaluate repair or l replacement of takeup bearing bushings, head shaft, or both. b. REPAIR or REPLACE takeup bearing bushings, head shaft, or both as directed by FLS or Engineering. l 4.10.5 INSPECT foot shaft bearings and foot shaft for excessive wear as follows: a. BOLT bearing halves together using U-bolts. b. MEASURE outside diameter of each foot shaft bearing p journal at two locations 90 degrees apart. L t ll %J MP 738.1 Level of Use ST P THINK ACT REVIEW Rev. 5 General 28 of 71

l 6 c. MEASURE inside diameter of each foot shaft bearing at two .lj locations 90 degrees ' part. a d. SUBTRACT foot shaft bearing journal measurements from corresponding foot shaft bearing measurements to obtain foot shaft bearing clearance. 4.10.6 E foot shaft bearing clearance is greater than or equal to 0.250 inch, PERFORM the following: a. REQUEST FLS or Engineering evaluate repair or l replacement of foot shaft bearings, foot shaft, or both, b. REPAIR or REPLACE foot shaft bearings, foot shaft, or both as directed by FLS or Engineering. _l 4.10.7 INSPECT screen sprockets as follows: a. EXAMINE for hooked sprocket teeth.- b. MEASURE surface thickness of sprocket tooth inserts. 4.10.8 REPAIR'or REPLACE screen sprockets as follows: p V' E sprocket teeth are hooked, REPLACE screen sprocket. a. b. E surface thickness of sprocket tooth inserts is less than j 1/4 nch, REPLACE all sprocket tooth inserts and associated i 1 mounting hardware. 1 4.10.9. Visually INSPECT drive sprocket and driven sprocket for hooked or worn sprocket teeth. 4.10.10. E drive sprocket sprocket teeth are hooked or excessively worn, REPLACE drive sprocket. NOTE Driven sprocket segments are reversible. 4.10.11 E driven sprocket sprocket teeth are hooked or excessively worn, REVERSE or REPLACE all driven sprocket segments as necessary. .o !%s Level of Use MP 738.1 General STOP . THINK ACT REVIEW Rev. 5 29 of 71 4

'N 1. e ] L i g3 . 4.10.12 ' Visually INSPECT drive chain for the following: b Corrosion l = o .. Chain roller freedom of movement without' excessive' side-to-side play. 4.10.13 IE drive chain is corroded or has excessive side-to-side play,- l

REPLACE drive chain.

l 4.10.14 INSPECT screen chains as'follows. a. EXAMINE screen chain for the following: I Corrosion around screen tray mounting holes L Chain rollers freedom of movement without excessive side-to-side play b. MEASURE removed chain pin in worn and unworn areas. l 4.10.15 REPAIR or REPLACE screen chains as follows: e ( a. 1E screen chain is corroded or has excessive side-to-side U play, REPLACE screen chain. b. IE chain pin worn and unworn measurements differ by greater than or equal to 0.030 inch, PERFORM the following: l

1) REQUEST FLS or Engineering evaluate repair or l

l replacement of screen chain. l

2) REPAIR or REPLACE screen chain as directed by FLS or Engineering.

l 4.10.16 Visually INSPECT screenwash components as follows: [

a. - EXAMINE spray pipe orifices for erosion and clogging.

l- /m v MP 738.1 l-Level of Use 1 STOP THINK - ACT REVIEW Rev. 5 j e m al 30 of 71 l I'

b. EXAMINE spray nozzles for the following: Erosion Fouling J Broken or deteriorated U-bolts c. EXAMINE splash plate for the following: Excessive wear Broken or deteriorated mounting bolts 4.10.17 REPAIR or REPLACE screenwash components as necessary. '4.10.18 INSPECT screen trays as follows: a. EXAMINE all cloth bolts for the following: Tightness Deterioration O

b.. EXAMINE screen cloth for holes.
c., EXAMINE tray frame for straightness.

3 d. EXAMINE screen cloth, and ENSURE screen mesh is /8 inch square, 4.10.19 REPAIR or REPLACE screen trays as necessary. 4.10.20 Visually INSPECT seal plates for excessive wear or damage. j 4.10.21 REPLACE seal plates as necessary. . 4.10.22. Visually INSPECT splash housings for the following: Cracks Holes Broken or missing latches on access doors O MP 738.1 Level of Use L General STOP THINK ACT REVIEW Rev. 5 l-31 of 71 l

L \\ j'"3 4.10.23 REPAIR or REPLACE splash housings as necessary. l Q,i l1 ' 4.10.24 ' Refer To MP 732.2," Traveling Water Screen Speed Reducer Repair," and PERFORM the following: I a. Visually INSPECT speed reducer for the following: l Dirt Moisture Signs of overheating a . Worn bearings and shafts Excessive backlash in gears-Oilleaks b. REPAIR or REPLACE speed reducer as necessary. l Electrician - l 4.10.25 Refer To MP 771.2,"Small AC Electric Motor Repair," and p PERFORM the following: V i a. Visually INSPECT motor for the following: Dirt Moisture Worn bearings and shafts - Signs of overheating-Signs of excessive vibration b. REPAIR or REPLACE motor as necessary.

()

L () MP 738.1 - ' Level of Use-- STOP THINK. ACT REVIEW - Rev. 5 General 32 of 71

... ~ . -. -.. -.. -.. - - ~.. ~. /~ l Mechanic -li 4.10.26 Visually INSPECT fluid coupling for the following: x)

  • Dirt Moisture -

= Signs of overheating Worn bearings and shafts Oilleaks a .4.10.27 REPAIR or REPLACE fluid coupling as ne~cessary. 4.10.28 Visually INSPECT flexible couplings for the following: Dirt Moisture Oil leaks. fg 4.10.29 REPAIR or REPLACE flexible couplings as necessary. A._/ ? s l l I-l I l l .p. r I f ' MP 738.1 . Level of Use ' THINK "ACT REVIEW-Rev. 5 STOP . General n 33 0f 71 .. ~,

i . ~. e.. 14.11 Cleaning and Painting m e Aj .\\ l Painter - l: 4.11.1 PAINT the following with two coats Bitumastic #300 black paint i followed by one coat Anti--Fouling Woolsley red paint: ^ i Head section I i Intermediate sections I Boot section 1

Screen chains Screen sprockets

- Drive sprocket ') Driven sprocket segmentc l '. - - : Head terminal Foot shaft i

([

'

  • L Screen' trays Seal plates 4.11.'2' IE existing paint is deteriorated, PAINT exterior housinus of it.c following with one coat;K&L Eye-liase green enamel p.um Speed reducer Coupling guard Motor -

= Chain guard a- = O h }p. l. -Qf I Level'of Use- ,1._. MP 738.1 o<-

General 3 STOP!

'THINK ~ _.' . AcT R.EVIEW Rev.5 s 4 p je g 34 of 71 i , ~..

1 li NOTE r v 1 Boot section assembly is illustrated in Figure 15. 1 1 4.12 Boot Section Assembly Figure 15 Boot Section Assembly .x x SHIM i

=

' : [ BOOT CASTING SIDE PuTE ! }QQh0UAL AROUNC BOOT ---zaf /4" 1/4 000T PLATE p TRAY WIDTH PLUS f,*gyA U ENLARGED SECTION AT AA UM "___8_[_^ .{ A {HE ADS OUTSIDE) TR AY WIDTH PLUS 3 5/8" l~ h

  • i !Sl

>L l l h' Il i i i SCREEN lO l { SPROCKET j g D 1 Q~./, - - ( p.m rUBOLT o COLLAR KEY fBEARING l L s, l g.. y fSHIM C 3 } ~ ) }. 's ( + SIDE ( 2'-2Y. ' R AD. 1/16" -> PLATE s f, 2*_4" R AD. e h, 'h a; S BOOT / \\ t g,, gA [,,, f k b y y C ASTING' I, i M {-], 000T PL ATE w _df j 'U ffg h yUM U ~+ +- TRAY WIDTH PLUS (HEADS O TSIDE FASTENERS @ HEXAGON HEAD BOLT 5/8 ' x 11/2" @ COUNTERSONK HEAD BOLT 5/8" x 11/2" @ SQUARE HE AD BOLT 3/4" x 21/4" @ WASHER 3/4" @ SQUARE HEAD BOLT 3/4" x 2-1/4" l Mechanic l 4.12.1 BOLT right boot casting to right side plate. 4.12.2 BOLT left boot casting to left side plate. 4.12.3 Loosely BOLT cross brace horizontally between opposite side plates. 7 t. (x.s i MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 Ceneral 35 of 71

I A e n

i...

t 4.12.4' Using shims as necessary to obtain uniform' spacing between top ~ ' surface of boot casting and top surface of boot plate, loosely j BOLT boot plate to boot castings. 4.12.5 _ ENSURE the following, then securely BOLT side plates to cross . brace and boot plate to boot castings: ' Side plates are square with boot plate Side plates are in line with and parallel to each other - a . NOTE Screen trays are 10.0 feet wide. i: Cross brace is shimmed as necessary to obtain spacing of 10 feet 15 1/16 nch) between flanges of opposite side: /16 nch ( i i plates l 4.12.6 IE bearing support brackets are bolt-on type, BOLT bearing support bracket to'each side plate. 4.12.7' Loosely ASSEMBLE screen sprockets and collars onto ends of L foot shaft. l' j. 4.12.8 RIG 2-ton lifting device to assembled foot shaft. 4.12.9 ENSURE top and bottom bearing halves are clean. l i '4.12.10 PLACE bottom bearing halves on bearing support bracket of each side plate. L 4.12.11. Carefully LOWER assembled foot shaft into boot section until O l ends of foot shaft rest on bottom bearing halves. L l. 4.12.12 ALIGN midpoint of foot shaft with lateral (side-to-side) i centerline of boot section. 1 4.12.13 PLACE top bearing halves onto bottom bearing halves and _ loosely BOLT to bearing support brackets with U-bolts. J [. o L4.12.14 DISCONNECT 2-ton lifting device from foot shaft. s .O i

Level of Use _

MP 738.1 ST P THINK ACT REVIEW . Rev. 5 L Generai 36 of 71

j f 1. j. lY"') 4.12.15 INSTALL shims under bottom bearing halves'as necessary to: 'v j LEVEL foot shaft. u 1 CENTER foot shaft 2-feet 2 /4-inches radially from boot castings. CENTER foot shaft 2-feet 4-inches radially from boot a. plate. 4.12.16 SLIDE screen sprockets and collars along foot shaft as necessary to: 5 OBTAIN 10 feet 3 /8-inch horizontal spacing between vertical centerline of sprocket teeth on opposite screen sprockets. POSITION screen sprockets symmetrically about lateral centerline of boot section. 4.12.17 TIGIITEN setscrews to SECURE screen sprockets and collars in adjusted positions. ,ns, L/ 4.12.18 SLIDE cach bearing along foot shaft as necessary to obtain 1/16-inch clearance between sprocket hub and bearing. - 4.12.19 TIGHTEN U-bolts to SECURE bearings in adjusted positions. 4.12.20 ENSURE foot shaft rotates freely in bearings. 4.12.21. EXAMINE all bolts for tightness. p.e 3 MP 738.1 = Level of Use STOP THINK ACT REVIEW ' Rev. 5 General 37 of 71

8 i? (M V NOTE Head section assembly is illustrated in Figures 16 and 17. 4.13 IIcad Section Assembly Figure 16 Head Section Assembly g + y LIFTING LUGS e CAPSTAN NUT WITH ROLLER THRUST E E ARING 6'

  • !I

I. . 9 i .i n. ,.. a ,N CHAIN TIGHTENER h' / d I I P W hl[ N< M ACHIN ERY SUPPORT Y R P d. I I > _ f T f l TAKEUP b w SiOE PANEL SCREW Y.4 E p IDE s FASTENERS I [ 'I M AND AT X W GREASE / ER EX E @ HEX AGON HE AD BOLT 5/8" a 1%" f @ HEX AGON HEAD BOLT 5/8"n 14" l @ HEXAGON HEAO BOLT 3/8"x %" + COVE R '__Y__.._. -[ t (, p'_ ____- _____._____-{l f )I / ,s i l, ,s r-4 __4 i v p [m asg \\ BEARING l L,_ hj t fun +--SCRE EN SPROCKETS TO BE __+ GASKET j i 4 l' CENTRALIZED IN FRAME N = / ( \\,1- \\ i >/ 'm. _. i j FRONT BRACE f,AC,K, a. B, k, c k :'k g,.

g. -

,_m-3.-.,_--..- k TR AY WIDTH PLUS 1'+1/8" JACK SCREW 1 1/8" HOLES l Mechanic l* 4.13.1 Loosely INSTALL the following to side panels: a. Front brace b. Back brace c. Machinery support 1 l n i MP 7381 Level of Use STOP THINK ACT REVIEW Rev. 5 General 38 of 71

[ a l L (N 4.13.2 ENSURE the following, then securely BOLT side panels to front s.; brace, back brace, and machinery support: Side panels are square with machinery support, front brace, and back brace. Side panels are in line with and parallel to each other. NOTE Screen trays are 10.0 feet wide. 1 i 1 Spacing of 11 feet 6 /8 nch ( /16-inch) is provided i between flanges of opposite side panels. 4.13.3 ENSURE grease port through each takeup bearing is clear. 4.13.4 IE head terminalis not assembled, ASSEMBLE head terminal as follows: 1 a. INSERT key in keyway on head shaft and SLIDE head shaft r's into torque tube. (\\s Figure 17 Head Terminal Assembly 1 Sr R T F ASTENERS. $C E SPR K T 9R j @ SOCKET HE AD CAP SCREW SEGMENT DRIVEN l . @ LOCKNUT SPROCK ET l SEGMENT e TOROVE TUDE l 4 KEY 9 mm4 A o ./ 1 S -ji gcda l e B C ,y TRAY WIDTH PLU$ 3-5/8" HALF HALF e6' SECTICN BB SECTION AA B A+ l b. Refer To dimension M specified on Figure 17 and ENSURE ends of head shaft project an equal amount from each screen l sprocket.

O MP 738.1 Level of Use ST P THINK ACT REVIEW Rev.5 General 39 of 71

_._._..~., a .s l uM c. TIGHTEN screen sprocket setscrews to secure head shaft in 1.. ) . adjusted position. - d. IBOLT driven sprocket segments to right screen sprocket.

e. ~ ENSURE takeup bearings and takeup bearing bushings are

. clean, f.- Refer To MP 791.0 (Att), " Circulating. Water (323)," and ? LUBRICATE takeun bearings and takeup bearing bushings. ' SLIDE takeup bearings a d ta: cup bearing bushings onto g. - ends of head shaft. '4.13.5 RIG mobile crane to head terminal. 4.13.6 HOIST and HOLD head terminal into position in head section. 4.13.7 INSTALL each takeup screw as follows: GUIDE takeup screw down through holes in machinery a. support and side panel to takeup bearing. ,..lp b. SCREW.takeup' screw in.to takeup bearing until stay bolt hole (d in takeup bearing aligns ~with stay bolt hole in takeup screw. i c. INSTALL stay bolt through takeup bearing and takeup screw. 4.13.8 ' INSTALL grease pipe to each takeup bearing. 4.13.9 INSTALL bolted channel section to each side panel. .i i 4.13.10 Using approved RTV adhesive, SEAL inside corners of takeup - ] bearing housings. .i 1 .4.13.11 Refer To MP 791.0 (Att)," Circulating Water (323)," and j LUBRICATE the following: Takeup bearing guides in side panels Threads of takeup screws

  • ' ddjoining faces of thrust bearings and capstan nuts 1

) !:, O 4.13.12 RAISE and HOLD head terminaljust into takeup bearing guides. 1 n "A_A. y MP 738.1

Level of Use
Meneral, STOP THINK ACT REVIEW -

Rev. 5 40 0f 71

O l l l..

O 4.13.13 INSTALL and TIGHTEN capstan nuts until head terminal is V

raised to lowest position of takeup travel. l 4.13.14 INSTALL and TIGHTEN jam nuts to lock capstan nuts into adjusted positions. 4.13.15 DISCONNECT mobile crane from head terminal. 4.13.16 INSTALL takeup bearing covers. C AUTIO N MP 790.4," Control of Heavy Loads," may apply to components moved - and handled in Section 4.14. NOTE 1 l Frame assembly and installation is illustrated in Figures 18 through 21. [) 4.14 Frame Assembly and Installation %) l Mechanic l 4.14.1 RIG mobile crane to boot section. 4.14.2 ENSURE the following and LOWER boot section halfway into suction well: Front side of boot section is facing influent water flow from Long Island Sound ] Boot section is positioned such that side panel guides align with guideways in suction well l 4.14.3 INSERT support bar halfway through lower hole of upper pair in i each side panel guide of boot section. l l O g L Level of Use MP 738.1 STOP THINK ACT REVIEW Rev. 5 General 41 of 71

(~ 4.14.4 LOWER boot section until support bars rest on operating ()} (building) floor. . Figure 18 Boot Sec'iion and Intermediate Section Installation - CROSS BEAM ~l SiOE PANEL INTERM ATE SUPPORT 7 E J / **" {OPERAT -[ f \\ / ) BOOTSECTION f N, 1 ___J 4 lA 4.14.5 ' DISCONNECT mobile crane from boot section. ('T 4.14.6 Loosely ASSEMBLE nonbmced intermediate section to boot section as follows: a. INSTALL side panels. b. INSTALL cross beams. i O V Level of Use MP 738.1 ST P THINK ACT REVIEW Rev.5 Genemi 42 of 71

1 V NOTE Screen trays are 10.0 feet wide. 4 4.14.7 1NSTALL shims between cross beam ends and side panels as itecessary to obtain spacing of.10 feet 15 i 1 /16 nch ( /16-inch) j between flanges of opposite side panels. Figure 19 i Diagonal Bracing Installation and Cross Beam Shimming i +. DIAGONAL BRACING - CROSS BEAM FASTENERS @ HEXAGON HE AD BOLT 5/8" x 1 1/2 @ COUNTERSUNK HE AD BOLT 5/8" x 1 1/2* @ HEXAGON HEAD BOLT 7/8" x 13/4" ,1 GUSSET PLATE MUST BE NEL {Sais ON SIDE SHOWN( !..; .. f<% b') (" 1 I~ } j o [,. ,.%g I I S, ~ SHIM SLOE PANELS TO OBTAIN-TRAY WlOTH PLUS 1/2'

II0,

^* TRAY WlOTH PLUS 1" MAX,7/8" MIN, ~ 4.14.8 ENSURE comporents of nonbraced intermediate section are plumb and square, then BOLT securely. 4.14.9 RIG mobile crane to nonbraced intermediate section. 4.14.10 Slightly RAISE partial frame (boot section and nonbraced intermediate section) and WITHDRAW support bars from boot section. ' 4.14.11 LOWER partial frame until nonbraced intermediate sectmn is halfway into suction well. 4.14.12 INSERT support bar halfway through lower hole of upper pair in each side panel guide of nonbraced intermediate section. (m Ah MP 738.1 Level of Use SW M M RM Re% 5 - General 43 of 71 i

a t l (~N ' 4.14.13 LOWER partial trame into suction well until support bars in y nonbraced intermediate section rest on operating floor. Figure 20 i Braced Intermediate Section Instaiiation ] CROSS BEAM l l ) '"'ss"c"$$^" BRACED DE i l l l ' [. SUPPORT BAR V D INT RM ATE .l n - E 3 ' BOOT SECTION gg r .S .0 4.14.14 DISCONNECT mobile crane from nonbraced intermediat: i section. 4.14.15 Loosely ASSEMBLE braced intermediate section to nonbraced i intermediate section as follows: a. INSTALL side panels. l b. INSTALL cross beams. ) c. INSTALL diagonal braces. 4.14.16 INSTALL shims between cross beam ends and side panels as 15 i 1 /16 nch ( /16-inch) necessary to obtain spacing of 10 feet between flanges of opposite side panels. A .N.] MP 738.1 Level of Use STOP THINK ACT REVIEW - Rev. 5 General 44 of 71

/D 4.14.17 ENSURE components of braced intermediate section are plumb V and square, then BOLT securely. 4.14.18 RIG mobile crane to braced intermediate section. 1 4.14.19 Slightly RAISE partial frame and WITHDRAW support bars from nonbraced intermediate section. i l l 4.14.20 LOWER partial frame until braced intermediate section is i halfway into suction well. 1 4.14.21 INSERT support bar haifway through lower hole of upper pair in each side panel guide of braced intermediate section. 4.14.22 LOWER partial frame into suction well until support bars in braced intermediate section rest on operr.iing floor. 4.14.23 DISCONNECT mobile crane fror2 braced intermediate section. i 4.14.24 Loosely ASSEMBLE top variable section to braced intermediate section as follows: L yp a. INSTALL side panels. t b. INSTALL cross beams. l 4.14.25 INSTALL shims between cross beam ends and side panels as 15/16 nch ( 1 necessary to obtain spacing of 10 feet i /16-inch) between flanges of opposite side panels. i j 4.14.26 ENSURE components of top variable section are plumb and square, then BOLT securely, 4.14.27 RIG. mobile crane to top variable section. 4.14.28 Slightly RAISE partial frame and WITHDRAW support bars from braced intermediate section. 4.14.29. LOWER rMial frame until top variable section is halfway into suction wel l l_ 4.14.30 INSERT support bar halfway through lower hole of upper pair in i each side panel guide of top variable section. AV 4 MP 738.1 Level of Use; 8# General 45 of 71 i - L.

I i j [ f [N 4.14.31 LOWER partial frame into suction well until support bars in top ' (,) variable section rest on operating floor. ) i - - Figure 21 l. Head Section Installation - I t i FRONT KNEE 1 BRACE BRACE 4 (BACK BRACE M itt AD SECTION PLAN JACK SCREWS L;! ia ~l: SIDE KNEE PANEL SUPPORT l OPERAT NG / BARS t, FLOOR f I SECT 80N -[ l TOP f VARIABLE SiOC VIEW -l f i I E J .# h l INTERMEDIATE g FASTENERS f l SECTION $ HEXAGON HEAD 1 kj, i BOLT 5/8" a 11/2" BRACED Il @ COUNTER $UNK HEAD I BOLT 5/8" x 1 1/2" - I' l :. l 1 1 i l - E J-l .j! I INTERMEDIATE { SECTION l -E 3 SCOT SECTION r 3 l BOTTOM OF WELL g I l 4.14.32 DISCONNECT mobile crane from top variable section. D' MP 738.1 . Level of Use STOP THINK ACT REVIEW Rev. 5 General 46 of 71

~. -... r .e-- h l I (f/Q 4.14.33 RIG mobile crane to head section. i i .4.14.34 ENSURE front side of head section is facing influent water flow. and POSITION head section onto top variable section. L 4.14.35 INSTALL head section securely to top variable section as follows: L, a. BOLT front of side panels to front brace of head section. l. b. BOLT rear of side panels to back brace of head section. c. BOLT knee braces between ends of back brace and each side panel. '4.14.36 Slightly RAISE entire frame and WITHDRAW support bars from top variable section. -4.14.37 DISCONNECT mobile crane from head section. l 4.14.38 BDLT boot section to suction well floor. 4.14.39 BOLT head section to operating floor. !A G 1 -) q ) b MP 738.1 -: Level of Use ST P THINK ACT ' REVIEW Rev.5 l. General 47 of 71

,f" ) NOTE 1. Screen chain installation is illustrated in Figure 22, 2. As illustrated in Figure 22, each screen chain is installed in three sequential sections; beginning,with the front section, followed by the top section, then the rear section. 4.15 Screen Chain Installation Figure 22 Screen Chain Installation 2nd $ECTION (Top) CAPSTAN NUT'rh f JAM NUT FRONTOF [h.. N SCREEN Y'/ ? L A TAKEUP '~ $L EST P TION s \\1._/, 73 l 1 \\, t-\\ lil SECTION (Front) 3rd 5ECTION (Rear) i i-t i i I j WATER,' ) {i'i, % i'i J FLOW E5 / N .h.-.I _ h l l Mechanic l 4.15.1 LOWER and LOCKfront section of each screen chain into front roller track angles as follows: i ! AL) MP 738.1 Level of Use STOP THINK ACT REVIEW Rev. 5 General 48 0f 71

l C A UTIO N 1. Screen chain can become twisted if handled improperly. Do not pick i up screen chain by hooking into the center of a coil. Support center of coil as shown below: DO THl3 g.

==_.

bdhD i AvolO THis 2. Do not feed screen chain on its side. Prevent the feeding screen chain in the manner shown below: possibility of twist by i l N AVOIDTHl3 s i a. RIG mobile crane tofront section of screen chain. Level of Use h1P 738.1 l General ST P M ACT REWEW Rev. 5 49 of 71

i !,a C A UTIO N Screen chains are directional,left-hand and right-hand opposite assemblies. Therefore, as shown below, the left-hand screen chain must be installed on the left side of traveling screen unit with the tapered link ends facing direction of chain travel. Similarly, the right-hand screen chain must be installed on the right side with the tapered link ends facing -j direction of chain travel. l g PIN LOCKS ON OUTSIDE OF CHAIN k l fi it I I ii Il I s LEFT HAND CHAIN CHAIN TRAVEL filGHT HAND CHAIN D' I :! !! l lIHiI s THESE HOLES MUST LINE luP IN BOTH CHAINS i N (es, 0 \\ (eA Q j CtO$$"TO sSIIFS"T"SNn"2,'tENa '%.) HOLE WHEN CHAIN IS INSTALLED b. ENSURE leading end of chain section is facing direction of chain travel and GUIDEfront section of screen chain down 'l into appropriate (left or right) front roller track angle. c. Fromfront of traveling screen unit and using locking bar, LOCKpont section of screen chain at upper screen sprocket. d. DISCONNECT mobile crane fromfront section of screen chain. .4.15.2 MOUNT top section of each screen chain onto upper screen sprockets as follows: a. RIG mobile crane tofront section of screen chain. l b. ENSURE leading end of chain section is facing direction of chain travel and GUIDE top section of screen chain onto appropriate (left or rif") upper screen sprocket. fs Level of Use MP 738.1 General sm m em Rew s l 50 of 71 m. +

r l^

n c.

DISCONNECT mobile crane from top section of screen l ! ) chain. C A U T I O N-1. Pin must be installed into chain joint with grease fitting facing outboard to facilitate chain joint lubrication. 2. Do not sand pin with emery cloth as life of chain may be decreased if fit between pm and chain joint is not water tight. 4.15.3 ENSURE chain pin grease fitting is facing outboard and using modified beam clamp, COUPLEfront and top sections of each screen chain. 4.15.4 LOWER and LOCK rear section of each screen chain into rear roller track angles as follows: L a. RIG mobile crane to rear section of screen chain. b. ENSURE lecding end of chain section is facing direction of chain travel and GUIDE rear section of screen chain down i[a) into appropriate (left or right) rear roller track angle. t c. From rear of traveling screen unit and using locking bar, LOCK rear section of screen chain at upper screen sprocket. I d. DISCONNECT mobile' crane fromfront section of screen chain. 4.15.5 ENSURE chair, pin grease fitting is facing outboard and using modified beam clan.p, COUPLE top and rear sections of each l screen chain. 4.15.6 UNLOCK each screen chain by removing locking bars. { l Diver l 4.15.7 ENSURE chain pin grease fitting is facing outboard and using modified beam clamp, COUPLE rear andfront sections of each screen chain. i l Mechanic l" 4.15.8 VERIFY each screen chain is installed such that leading end of chain is facing direction of chain travel. y m. O h1P 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 l-ggggg 51 of 71

l ~ l l "~) / i (,) NOTE l l Screen chain adjustment is illustrated in Figure 23. 4.16 Screen Chain Adjustment Figure 23 Screen Chain Adjustment CAPSTAN NUT g 3, i, p. __ u cJ,N!nv.u,,onta.

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s p< 2.j i i, _ n u: q.. -c l l gj 7 ggy [se,n ew, M., s, s f '-l T i \\ \\ h_' f \\1 ~ / f.. qp 'q pf3 i L _ _ _ _ _"_c^"m ^=rJ_ _ _. t I ,e ,2 - { F._- -- ______p [. 1

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C. _ _ _-- _ _ _ _ _ _ _ _^_ T_T \\ df ac^mac r- \\ J / 1 m x l \\ j' / 1 ll l u %. _. q,- l are fj iI ,- v,ny -- a ww- - g l C AUTIO N Screen chains must be'sufficiently tight to keep them in place on lower screen sprockets. If screen chains are loose, undue wear will occur on sprocket teeth and chain rollers; if extremely loose, damage will result from accumulation of excess slack at point where descending chains join lower screen sprockets. l l l Mechanic l* 4.16.1 LOOSEN jam nut on each takeup screw. l 4.16.2 ADJUST capstan nuts as necessary to LEVEL head terminal. ,m. t i N./ MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 i General 52 of 71 \\ l l

~ 4 NOTE 1.~ When adjusting screen chains, turn capstan nuts the same number of j turns so that head terminal remains level while screen chain tension is increased. Capstan nuts have six threads per inch.- l-l- - 2.' There is approximately 10 /2-inches of head terminal takeup travel 1 available for screen chain adjustment. 4.1'6.3 Simultaneously and equally TURN both capstan nuts to RAISE leveled head terminal until both screen chains are tight.- 1 4.16.4 BACK OFF each capstan nut 1/2-turns to obtain running freedom. 4.16.5. TIGHTEN jam nuts to LOCK capstan nuts into adjusted positions. ~A.V ? L C) MP 738.1 Level of Use ST P THINK ACT REVIEW Rev. 5 General 53 ef 71 ~.

l 1 4 i -\\v NOTE Motogear installation is illustrated in Figure 24. 4.17 MotogearInstallation and Alignment l Mechanic l* 4.17.1 RIG 1-ton lifting device to speed reducer. 4.17.2 LIFT and PLACE speed reducer on drive platform. 4.17.3 BOLT speed reducer to drive platform using shims under feet of speed reducer as necessary to: a. LEVEL speed reducer, b. SUPPORT speed reducer uniformly under each foot. c. ALIGN speed reducer output shaft parallel with head terminal. 4.17.4 DISCONNECT 1-ton lifting device from speed reducer. 4 ' (./ Figure 24 Motogear installation FLUID COUPLING COUPLING GUARD RfGIO SIDE TO MOTOR FLEXIBLE COUPLING SPE ED REDUCE R MOTOR SHAFT KET CHAIN GUA10 f "$ A h * ' skims (" /, _f l ~ SHIMS NF -i e, _s l DRIVE PLATFORM 2 \\ DRIVEN + SPROCKET g s 8 3 w....y / / -EE=.E:EEEg[2 sg aAr-l s\\ '~ ,e l -'y () MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 General 54 of 71

I ~ + p l /q 4.17.5 SLIDE or TAP drive' sprocket onto speed reducer output shaft. '4.17.6 : ' ALIGN drive sprocket plumb and square with driven sprocket. l 4.17.7 TIGHTEN drive sprocket setscrews. 4.17.8 RIG 1-ton lifting device to motor. 1 '4.17.9 LIFT and PLACE motor on motor bracket. 4.17.10 Using fluid coupling as gage, POSITION motor from speed reducer so that clearance between ends of the following shafts equals dimension stamped on flexible coupling hubs: Fluid coupling shaft and motor output shaft Fluid coupling shaft and speed reducer input shaft 4.17.11 Loosely BOLT motor to motor bracket using shims under feet of motor as necessary to: a. LEVEL motor.

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b. SUPPORT motor uniformly under each foot, c. ALIGN motor output shaft approximately concentric with speed reducer input shaft. ) 1 4.17.12 DISCONNECT 1-ton lifting device from motor. . ;^ j.:V Iv1P 738.1 Level of Use ST P THINK ACT REVIEW - Rev.5 General 55 of 71 q n.

L^ l 1 C AUTIO N Avoid heavy hammer blows when mounting flexible couplings and drive sprocket as there may cause damage to gears and bearings. Flexible couplings and dt./e sprocket may be heated between 150 F and 200 F to expand component sufficiently to slide or tap onto shaft. 4.17.13 SLIDE or TAP flexible coupling halves onto the following shafts such that end of hub and end of shaft are flush: l' Speed reducer input shaft Motor output shaft Each end of fluid coupling shaft i NOTE All horizontal and veitical adjustments for motor output shaft-to-speed - ) reducer input shaft concentric alignment should be performed at the motor ,7S to maintain speed reducer output shaft-to-head terminal parallel Q alignment. ' 4.17.14 Using traveling screen coupling alignment tool and shimming at motor only, ALIGN motor output shaft concentrically with speed reducer input shaft per the following specifications: l l Face-to-face alignment of less than or equal to 0.002-inch l Rim-to-rim alignment of less than or equal to 0.004-inch 4.17.15 ENSURE motor and speed reducer mounting bolts are tight. 4.17.16 RIG 1-ton lifting device to fluid coupling with attached flexible coupling halves. 4.17.17 ENSURE rigid side of fluid coupling faces motor and POSI7

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fluid coupling, with attached flexible coupling halves, between i. speed reducer and motor. i 4.17.18 BOLT all flexible coupling halves. 'p 4.17.19 DISCONNECT. . lifting device from fluid coupling. ,V MP 738.1 i Level of Use -ACT REVIEW Rev. 5 sroe Tsinx L General 56 of 71 I

(~T 4.17.20 IE motor-to-speed reducer alignment required adjustment of () speed reducer shimming, REPEAT alignment of drive sprocket to driven sprocket. l Electrician l* 4.17.21 INSTALL flexible conduit and ground cable to head section. 4.17.22 CONNECT electrical wiring and ground cable to motor. 4.17.23 CLOSE electricaljunction box on motor. 1 NOTE Drive chain installation is illustrated in Figure 25. 4.18 Drive Chain Installation l Mechanic l' 4.18.1 ENSURE chain tightener is adjusted to allow maximum slack in drive chain. Figure 25 Drive Chain Installation [ SPEEO REOUCER (j /3 7 $PROCKET CHAIN GUARD cm yJa,,W a Hy ,r \\_. n=21W c. W g o r q f c- _ __r l q g $P O ET l 2 5 1't 3

3....g Q

I / I I 4 6 s fE:::.T:::::::::.525] [5 s hy;,, 3 ,. w \\ N.x w + H-- l A l (~'., 'L J MP 738.1 Level of Use General ST P THINK ACT REVIEW Rev. 5 - 57 of 71 l

C A UTIO N ' Drive chain is a directional assembly. Leadinfee detailin Figure 25.) end of drive chain has wider spacing between opposite link plates. ( l l 4.18.2 ENSURE leading end of drive chain is facing direction of chain - travel and MOUNT drive chain on drive sprocket and driven sprocket as follows: l l a. LIFT and GUIDE drive chain over drive sprocket. b. Using rope, FEED drive chain under chain tightener and around driven sprocket. l i 4.18 3 VERIFY drive chain is installed such that leading end of drive l chain is facing direction of chain travel. L 4.18.4 COUPLE drive chain as follows: a. ENGAGE leading and trailing ends of drive chain. b. INSERT pin at inboard side into chain joint pin hole. L Using modified beam clamp, DRIVE pin flush and centered c. into chain joint. ) i I i G M MP 738.1 Level of Use ST P THINK ACT REVIEW Rev. 5 General 58 of 71

l '. / \\ C AUTIO N Excessive wear o 1 drive chain will occur if drive chain is too long. Length of drive chain must be adjusted as required so that minimal cham l tensioning is nece.ssary. Adjustment of drive chain is shown below: SPEED REDUCER SPEED REDUCER CHAIN GUARD CHAIN GUARD W o Q l viGurtuta ricm EnEn c'.o a L ~ (m r '1 j N\\ Daivfu OnivEn senDCxer senDCxEr s i g y 41F, f,./* ~."... N e ./ a licsl M's! '/ / i'?. 4 4- , M.4...-. w DO THIS AVOID THIS p 4.18.5 IE drive chain is too long, REMOVE links as required so that (j minimal chain tensioning is necessary. NOTE Drive chain must be adjusted after screen chains have been adjusted. 1 4.19 Drive Chain Adjustment l Mechanic l* 4.19.1 LOOSEN chain tightener mounting bolts. 4.19.2 ROTATE chain tightener until chain rollers of drive chain seat snugly into teeth of driven sprocket. 4.19.3 BACK OFF chain tightener slightly to obtain running freedom. 4.19.4 TIGHTEN chain tightener mounting bolts. !fs' 1! Level of Use MP 738.1 STOP THINK ACT REVIEW Rev. 5 ggggg 59 of 71

.. ~ -.. 1 l 1' l tm. lV NOTE l [ Lubrication points for traveling screen unit are illustrated in Figure 26. I 4.20 - Lubrication Figure 26 l Traveling Screen Unit Lubrication SPEED CAPSTAN NUT WTH TH RUST FLUID COUPLING jL BEARING f P 7 CHAIN MOTOR d,, / TIGHTENER j g_ CHAIN { hTAKEUP FLEXIBLE COUPLING g l BE ARING c l 'd n 7 4 R.J / 'il 50 R *% Q::== / [,," h CHAIN JOINT g SECTION THROUGH CHAIN JO!NT l Mechank, l 4.20.1 Refer To MP 791.0 (Att), " Circulating Water (323)," and l LUBRICATE speed reducer (reduction gear) as follows: a. REMOVE upper " OIL LEVEI" plug on front of speed reducer flange housing. b. REMOVE breather at top of speed reducer flange housing, c. POUR oil into breather hole until oil exits from " OIL LEVEI" plug hole. d. CLEAN and INSTALL upper " OIL LEVEI" plug. c. CLEAN and INSTALL breather. L, j MP 738.1 Level of Use STOP THINK ACT REVIEW Rev. 5 ggggg 60 of 71 l

L l ls 4.20.2 Refer To MP 791.0 (Att)," Circulating Water (323)," and l L. I LUBRICATE each flexible coupling as follows: OPEN cover on flexible coupling housing. a.

b. - SLIDE sleeve out from hub.

c. PACK hub with grease. d. SLIDE sleeve back to hub. -e. ' CLOSE cover on flexible coupling housing. 4.20.3 LUBRICATE fluid coupling as follows: NOTE Fluid coupling oil filler 31ug must be positioned at 36 degrees from vertical-when replenishing oil. The " Top For Filling" stamp on tae fluid coupling, when vertical, marks the proper fluid coupling position for replenishing oil. -l ~

a. - ROTATE fluid coupling to POSITION " Top For Filling" n

stamp at top of fluid coupling. yr b. REMOVE oil filler plug. Refer To MP 791.0 (Att), " Circulating Water (323)," and l c. POUR oil into oil filler plug hole until oil exits from oil filler plug hole, d. CLEAN and INSTALL oil filler plug. 4.20.4 Refer To MP 791.0 (Att), " Circulating Water (323)," and l LUBRICATE motor as follows: INSERT grease gun onto motor grease fitting. a. b. INJECT two shots of grease. c. REMOVE grease gun. l!P l Level of Use MP 738.1 General. ST P THINK ACT ' REVIEW Rev. 5 61 of 71

c l f3 4.20.5 Refer To MP 791.0 (Att), " Circulating Water (323)," and j. d - LUBRICATE each takeup bearing as follows: 3 a.- OPEN takeup bearing access' cover.

b. -INSERT grease gun onto takeup bearing grease fitting and INJECT until grease oozes out of takeup bearing.
c. ' REMOVE grease gun.-

d. CLOSE takeup bearing access cover.: 4.20.6 Refer To MP 791.0 (Att), " Circulating Water (323)," and l LUBRICATE chain tightener bearing as follows: a. INSERT grease gun onto chain tightener grease fitting, b. INJECT two shots of grease. c. REMOVE grease gun. 4.20.7 REQUEST Operations Department jog one revolution of e. traveling screen rotation and CHECK traveling screen unit for 4 d the following: . Proper direction of traveling screen rotation No interference, binding, or obstructions to movement 4.20.8 REQUEST Operations Department start traveling screen rotation. .4.20.9 = Refer To MP.791.0 (Att)," Circulating Water (323)," and, using - l grease gun fitted with Alemite #Z-737 nozzle, LUBRICATE each screen chain as follows: a. MARK or SCRIBE convenient chain joint for indication of lubrication starting point. b. GREASE each chain joint as follows until lubrication starting point has been passed: i .1) WHEN chain joint becomes accessible, quickly INSERT grease gun into. chain pin grease fitting and INJECT until l-grease oozes out of chain joint.

v)

.t MP 738.1 i . Level of Use ST P THINK AT REVIEW Rev. 5 l-Generaf'- 62 of 71 i-

L. 4 e i fl (}

2) REMOVE grease gun.

l'n.J 4.20.10 Refer To MP 791.0 (Att)," Circulating Water (323)," and, using l l applicator paddle, LUBRICATE entire drive chain. 4.20.11 REQUEST Operations Department stop traveling screen l rotation and deenergize traveling screen unit. 4.20.12 INSTALL chain guard to head section, i NOTE Spray pipe installation is illustrated in Figure 27. 4.21 Spray Pipe Installation Figure 27 Spray Pipe Installation 1 T STAGGERED N SPRAY NO2ZLE s b 3* 135* h./ FASTENERS 7 @ HEXAGON HEAD BOLT 5/8 x 13/4" /,/ ~

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@ BEVEL WASHER 6/8 @ HEXAGON HE AD BOLT 1/2 x I" s @ HEXAGON HEAD BOLT 3/8 x 1" ? '\\ \\ rsw m rag-- ~ l~ C/L l i ~ * *' OR M --SPLASH PLATE \\ dr" - pg 1 U-BOLT 4 i ;.. ~ ASSE 8 /SPLif SEAL , ' '. bk7 ~ e, 1 . w $U.PPDM.T / T p o 4.2i::= ::.=:i2:.M::.=:& 5 E e m ____l___________________________d BOLTS @ FRONT BRACE =* \\ VALVE b FEED PIPE ASSEMBLY b BACK BRACE = l Mechanic l 4.21.1 ENSURE traveling screen unit is deenergized. 4.21.2 RIG 1-ton lifting device to midpoint of spray pipe with attached l supports. l A 4.21.3 MOUNT spray pipe with attached supports to front brace. (v) i - MP 738.1 Level of Use STOP THINK ACT REVIEW Rev. 5 gggggy 63 of 71

L.D 4.21.4. BOLT supports securing spray pipe to front brace. l V i 4.21.5 DISCONNECT 1-ton lifting device from spray pipe. 4.21.6 RIG 1-ton lifting device to outboard end of feed pipe. -4.21.7. PUSH feed pipe inward through feed pipe penetration in head section side panel to spray pipe. L 4.21'.8 ' CONNECT piping union between spray pipe and feed pipe. l 4.21.9 CONNECT feed pipe to screenwash header. 4.21.10 ' DISCONNECT 1-ton lifting device from faed pipe. 4.21.11 INSTALL split seal at feed pipe penetration in head section side panel. 4.21.12. IE feed pipe is equipped with screenwash supply pressure indicator, CONNECI'screenwash supply pressure indicator and associated conduit to feed pipe. fs 4.2L13 INSTALL splash plate.to back brace of head section. D l MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 ggggg 64 of 71

i l NOTE Screen tray installation is illustrated in Figure 28. 4.22 Screen 'IYay Installation Figure 28 Screen Tray installation FASTENERS D CARRIAGE BOLT 3/4" a 41/2" E LOCKNUT 3/4" ,f b l l l, lI I / i l l i 1 I d, p ^ j M. \\\\ b 42:=" ) gg g O i CHAIN 4i i i=. SEAL PLATE c, 'I lh [ .II$I" E

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= TRAY b[ O O e TRAY \\ d 1 l *' T 7E AL PLATE I l Mechanic f 4.22.1 REQUEST Operations Department energize traveling screen unit. i f .i( MP 738.1 Level of Use stoP THINK ACT REVIEW Rev.5 General 65 of 71

=.- l l k C AUTIO N' \\ l Screen trays must be installed in groups of up to four at crisscross locations around the screen chains in order to e chains during screen tray installation. qualize weight balance on screen l t i NOTE l There are 43 screen trays per traveling screen unit. 4.22.2 INSTALL group of maximum four screen trays to screen chains as follows: Using block and wedge, BLOCK speed reducer input shaft. a. l b. Starting with lowest screen tray and working up,_ INSTALL each screen tray of group as follows:

1) RIG 1-ton lifting device to midpoint of screen tray.

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2) LIFT and PLACE screen tray in position between left-hand and right-hand screen chains.
3) INSERT and HOLD seal plates between ends of screen tray and inboard side bars of left-hand and right-hand i

screen chains.

4) BOLTleft-hand and right-hand screen chains to screen tray.
5) DISCONNECT 1-ton lifting device from screen tray.

c. UNBLOCK speed reducer input shaft by removing block and wedge. 4.22.3 REQUEST Operations Department jog traveling screen rotation i as necessary to access crisscross locations around screen chains and REPEAT step 4.22.2 until all screen trays have been installed. 4.22.4 INSTALL coupling guard to head section. ,f w ,b MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 General 66 of 71

L ~ 1 L, m ' i ,n 4.23 OperationalTest i LU L l Mechanic l 4.23.1 REQUEST Operations Department run traveling screen rotation .l - for 1 hour test period, and PERFORM the following during test. g -period a. OBSERVE traveling screen rotation and CHECK for the - following: ' No rubbing of seal plates on side panel flar.ges -No rubbing of screen tray ends on roller track angles No dragging of screen trays around boot section

b. - REQUEST Operations Departnient activate screenwash function.
c. ' OBSERVE screenwash spray action and ENSURE the i

'following: , Spray nozzle orifices are clear + Spray nozzles are correctly positione'd ' Spray pressure is normal : d. REQUEST Operations Department deactivate screenwash function. CHECK the following for signs of excessive heating due to c.- tightness or misalignment:- Motor bearings Speed reducer bearings Drive chain rollers Screen chain rollers Takeup bearings _ L: 4.23.2 WHEN 1 hour test period is complete, REQUEST Operations p{J ~ traveling screen unit. Department stop traveling screen rotation and deenergize l-MP 738.1 Level of Use Rev. 5 STOP -THINK ' ACT REVIEW - ggggg - 67 of 71

AV NOTE Splash housing installation is illustrated in Figure 29. 4.24 Splash IIousingInstallation Figure 29 Splash Housing Installation SPLASH SEAL PLATE 1 SIDE PANEL 2 rf BOLTS @ I~ a U RucseR eASKET:, TRAY SEAL PLATE - M.: .] ~. HEAD SECTION SIDE PANEL'. f '[ ~ a Nti I ,I INTERMEDIATE SIDE PANEL, -it-l SECTION AA I ans. 3 cms 1"' E^ J y,two! ~. o '1 B . :p + N P, 7 g h N .i t ' ' -____._______._h__ SHELF \\ GASKET 1 /kUfh . M'.; i - 2 CHUTE

=

SHELF FASTENERS j' F HEX AGON HE AD BOLT 3/8" x 1 1/4" G HEXAGON HEAD DOLT 5/10" x 11/4" 1 CONCRETE I Mechanic l* 4.24.1 ENSURE traveling screen unit is deenergized. 4.24.2 INSTALL splash seal plate to access door frame on right side of front splash housing. 4.24.3 Using neoprene rubber material, FABRICATE rubber gaskets for front splash housing and rear splash housing. 4.24.4 RIG 1-ton lifting device to front splash housing. 4.24.5 INSTALL front splash housing with gasket +o head section. 4.24.6 DISCONNECT 1-ton lifting device from fro..', lash housing. MP 738.1 Level of Use STOP THINK ACT REVIEW Rev.5 General 68 of 71

) i p o-i !, gi 4.24.7 INSTALL permanent ladder to operating floor and head section - g Q at front splash housing. 4.24.8 ~ RIG 1-ton lifting device to rear splash housing. 4.24.9 INSTALL rear splash housing with gasket to head section. l L 4.24.10 DISCONNECT 1-ton lifting device from rear splash housing. 4.24.11 ENSURE hinged shelf above trash trough is free to operate. 4.24.12. BOLT splash seal plate to access door frame on right side of front i splash housing. 4.24.13 ENSURE all splash housing access doors and access hatches are closed.- 4 4.24.14 NOTIFY Operations Department traveling screen unit overhaul is completed. 4.24.15 Refer To AWO and COMPLETE Actual Work Performed section. (~y (.) 1 . f. l l i-l' l. 4 l. p~ () MP 738.1 Level of Use ST P .THINK ACT REVIEW - Rev. 5 . General 69 of 71 1

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5. REVIEW AND SIGN-OFF G

5.1 The review and sign-off for this procedure is satisfied by the review and. sign-off of the AWO.

6. REFERENCES -

6.1 NNECo Accident Prevention Manual 6.2 Vendor Manuals 6.2.1 25202-443-001 A, FMC " Link-Belt Traveling Water Screens Models 45A and 46A Service Instruction 2690" 6.2.2 " Link-Belt Gearmotors'and Motogears Service Instructio:is and Parts List 2696" 6.2.3 " Link-Belt Type SG Geared Shaft Couplings Service Instructions 3104" (3 Administrative Procedures j 6.3.1 CC 1, " Control of Chemical Consumable Products" t 6.3.2 WC 4, " Confined Space Entry" U l 6.4 Maintenance Procedures 6.4.1 MP 732.2," Traveling Water Screen Speed Reducer Repair"- N 6.4.2 MP 771.2,"Small AC Electric _ Motor Repair" 6.4.3 MP 790.4," Control of Heavy Loads" 6.4.4 r MP 791.0 " Plant Component Lubrication" l 6.5 Other Documents 6.5.1 Maintenance Department Purchase Order (MPO) File #748 i I ysb b MP 738.1 L Level of _Use m _~_,A ,.m-._ 'ST P' ' THINK' 4ACT" REVIEW Rev. 5 GOneral

cq

.,t, j.. /s ' 70 of 71

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SUMMARY

OF CHANGES plQ . 7.1. This procedure was revised as a result of a Biennial Review. Minor l editorial and reference changes were made. 7.2 Incorporated interim change 1 which deleted Chemistry Department from responsibility of performing closed volume sampling. This task is now-performed by Health Facility EMTs. _/ i 7.3 Incorporated interim change 2 which added' step to inspect screen cloth and ensure that screen ineshi 3 a indl. This 4.vas done in response to ACR 7412. 1 -7.4 Incorporated interim change 3 which added references to MP 791.0 " Plant Component Lubrication."' u e 'es 5: v c a in 1 %/ Level of Use MP 738.1 General. STOP

THINK,

ACT REVIEW - Rev,5 1 71'of 71 _ _ _ _ -._}}

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