Manual Bomba 450 m150-Mcr--g-rr Of53959,60 Nv 5020

ISSUED MAY 2010

INDICE

I. Drawing List 1. 2. 3. 4. 5.

General Arrangement Drawing Curve Component Diagram Bearing Assembly Part List

II. Assembly and Maintenance Instructions - SUPPLEMENT “M1” General Instructions Aplicable to All Types of Warman Pumps

III. Assembly and Maintenance Instructions - SUPPLEMENT “MDS12” Sizes “250-650” Slurry Pumps – Type “MCR”

IV. Assembly and Maintenance Instructions - SUPPLEMENT “MDS14” Basic Bearing Assembly - Series “M” (Frame Sizes M100, M120, M150, M180, M200, M240)

V. Assembly and Maintenance Instructions – SUPPLEMENT “M09” Gland Sealing

Mill Circuit Pump CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (to ANSI/HI 1.6-1994 Centifugal Pump Test Standard). For media other than water, corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.

Issued: 07/1996 Last Issued: 09/1998

Rubber Lined

70

MOTOR 500 HP (usara motor de 800 HPEXISTENTE)Metal/Rubber Suction Side Liner BOMBA 330 RPM 20" Suction HR= 1 18" Discharge ER= 1 Gr. Esp. pulpa 1,123 1429mm Dia. 5 Vanes

TAG. C-3420-PP-512/513 Speed 400 rpm

60

60% 70%

Metal Impeller 178mm Max. Sphere Size

75% 80% 83%

50

85%

Hydroseal ® 85%

350 rpm

40 300 rpm DP02

30 250 rpm 20 200 rpm

10

Flow=4166 m³/h Head=33 m Speed=326 rpm Efficiency=85.1 % NPSHr=6.1 m Power=440.2 kW at Sm=1.0 9.1

DP01 Flow=2083 m³/h Head=33 m Speed=305 rpm Efficiency=73.4 % NPSHr=2.8 m Power=255.3 kW at Sm=1.0

MIN 1.8 (m) NPSHR

(m)

7.6 (m)

BHP = kW

6.1 (m)

=

usgpm x ft x SG 3960 x Efficiency m³/hr x m x SG 376 x Efficiency

m³/hr = 0.227 x usgpm m = 0.3048 x ft SG = Specific Gravity

2.4 (m)

4.9 (m) 3.7 (m)

© Copyright 10/2009 Weir Slurry Inc. All Rights Reserved. TYPICAL PUMP PERFORMANCE CURVE

P-4801C 0 0

2000

4000 Flow, Q (m³/h)

6000

8000

450 MCH

Printed by wsCurve 1.0 build 0200 14 Oct 2009

Head, H (m)

83%

IR A MENU Weir Minerals Latin America

ASH PUMP

Vulco Perú S.A. PERU S.A. Listado de Partes

A Weir Group company

WARMAN 450 M150-MCR-G-RR TIPO SELLO GLAND ITEM 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

A2-110-0-385925 Rev.3 REVESTIMIENTO EN CAUCHO NATURAL

DESCRIPCION

*

* * * * * * * * * *

* * * * * * * * * * * * *

BEARING ASSEMBLY FRAME PLATE ADAPTER BOLT SHAFT SLEEVE SEAL GUARD SEAL GUARD SET SCREW GLAND (2 PIECE) INCLUDES (2) M12H1-65SN STUFFING BOX FRAME PLATE LINER INSERT FLAT WASHER HEX NUT FRAME PLATE ADAPTER STUD-1 NUT-1 WASHER BOLT, FRAME PLATE PUSHER LINER STUD - 1 NUT - 1 WASHER FRAME PLATE FRAME PLATE LINER COVER PLATE STUD M64 ANTI-ROTATION NUT DISCHARGE JOINT RING WASHER NUT COVER PLATE LINER COVER PLATE STUD, SUCTION COVER 1 NUT + 1 WASHER THROATBUSH SUCTION COVER COVER PLATE STUD - PULLER FLAT WASHER HEX NUT IMPELLER INTAKE JOINT RING O-RING COVER PLATE BOLT - PUSHER FRAME PLATE LINER INSERT STUFFING BOX BOLT - 1 WASHER LANTERN RING (SPLIT) PACKING RING GLAND BOLT - 1 NUT - 1 WASHER NAMEPLATE TAG, IMPELLER REMOVAL TAG, BURSTING TAG, LITING ALIGNMENT PIN NAMEPLATE - WARMAN NAMEPLATE - WEIR MINERALS FRAME PLATE ADAPTOR

* INDICATES RECOMMENDED SPARE PARTS

CANT

CODIGO VULCO

1 8 1 1 ? 1 1 4 4 4 7 8 16 1 1 14 14 1 14 14 1 1 16 1 1 4 4 4 1 1 1 4 1 8 1 4 4 1 1 1 1 2 2 2 1

M150205SYN M24H1-70V M150076 C21 TBA TBA TUMC044 C21 TUMC078 D20 ZSD80294C E62 M24-11-Z M24H5-V M48Z3-120VC M42A4-100V M24Z3-90VC M150MCR45395 D20 310173 R55 UMCR40015A UMCH65284 310178 S90 M64-11-Z M64H5-V 310174 R55 UMCR45394 D20 M36Z3-100VC UMC45083 R55 UMCR45190 D20 ZSD80294H M24-11-Z M24H5-V TUMC45145EL1 A08 UMC45060 R55 T109 S50 M42H2-150V UMC45041 R55 M20H1-55VW TUMC118 K31 TUMC111 Q21 TUMC45045 C23 NPL1989 C22 SC83 C22 SC73 C22 SC80 C22 UMCH55489 E22 PA91 C22 WA90 C22 M150MC45380 D20

Weir Minerals Latin America Vulco Perú S.A. Listado de Partes

WARMAN 450 M150-MCR-G-RR A2-110-0-389235 Rev.0

BEARING ASSEMBLY M150205SYN ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

DESCRIPCION * SHAFT * SHAFT KEY * BEARING ISOLATOR - DRIVE END END COVER - DRIVE END END COVER SET SCREW - DRIVE END * O-RING - DRIVE END * GREASE FITTING BEARING HOUSING * O'RING - IMPELLER END END COVER SET SCREW - IMPELLER END END COVER - IMPELLER END * FLINGER * SET SCREW RELEASE COLLAR * COVER RELEASE COLLAR * O-RING - COVER RELEASE COLLAR * WEDGE SET RELEASE COLLAR * O-RING - WEDGE RELEASE COLLAR BEARING ISOLATOR - IMP. END * BEARING (IMPELLER END) * BEARING (DRIVE END) * BEARING TONGUED WASHER BEARING WASHER BEARING LOCKNUT NAMEPLATE * INDICATES RECOMMENDED SPARE PARTS

CANT 1 1 1 1 8 1 2 1 1 8 1 1 8 1 1 1 1 1 1 1 1 1 1 1

CODIGO VULCO M150254 E23 T070 E05 M150482D M150024 D20 F027M E62 53T330N382 ZST14MS M150004 D20 53T304N381 M16H2-40V M150023 D20 M150184 M20A2-20V M150239B E62 35T203N266 M150239A E02 53T149N360 M150482 T009D T009 M150506 E02 SKFMB33 SKFKM33 NPL97 C22

ISSUED: MAY 1999

WARMAN INTERNATIONAL LTD

WARMAN PUMPS ASSEMBLY AND MAINTENANCE INSTRUCTIONS SUPPLEMENT ‘M1’

Warman International Ltd. is the owner of the Copyright subsisting in this Manual. The Manual may not be reproduced or copied in whole or in part in any form or by any means without the prior consent in writing of Warman International Ltd.

Date Issued 14/05/99 Copyright

©

WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

WARNINGS IMPORTANT SAFETY INFORMATION • The WARMAN PUMP is both a PRESSURE VESSEL and a piece of ROTATING EQUIPMENT. All standard safety precautions for such equipment should be followed before and during installation, operation and maintenance. • For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable speed drives, etc.) standard safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment and maintenance. All guards for rotating parts must be correctly fitted before operating the pump including guards removed temporarily for gland inspection and adjustment. • DRIVER ROTATION MUST BE CHECKED before belts or couplings are connected. Personnel injury and damage could result from operating the pump in the wrong direction. • DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS FOR PROLONGED PERIODS, OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORISE. Personnel injury and equipment damage could result from the pressure created. • DO NOT APPLY HEAT TO IMPELLER BOSS OR NOSE in an effort to loosen the impeller thread prior to impeller removal. Personnel injury and equipment damage could result from the impeller shattering or exploding when the heat is applied. • DO NOT FEED VERY HOT OR VERY COLD LIQUID into a pump which is at ambient temperature. Thermal shock may cause the pump casing to crack. • FOR THE SAFETY OF OPERATING PERSONNEL, please note that the information supplied in this Manual only applies to the fitting of genuine Warman parts and Warman recommended bearings to Warman pumps. • LIFTING PUMP COMPONENTS • Tapped Holes (for Eye Bolts) and Lugs (for Shackles) on Warman Parts are for lifting Individual Parts Only. • Lifting devices of adequate capacity must be used in conjunction with these assembly and maintenance instructions wherever they are required to be used. • Sound, safe workshop practices should be applied during all assembly and maintenance work. • Personnel should never work under suspended loads. •

Date Issued 14/05/99 Copyright

©

WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

FULLY ISOLATE THE PUMP before any maintenance, inspection or troubleshooting involving work on sections which are potentially pressurised (eg casing, gland, connected pipework) or involving work on the mechanical drive system (eg shaft, bearing assembly, coupling):• Power to the electric motor must be isolated and tagged out. • It must be proven that the intake and discharge openings are totally isolated from all potentially pressurised connections and that they are and can only be exposed to atmospheric pressure.

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

ISSUED: MAY 1999 LAST ISSUE: OCTOBER 1998 WARMAN PUMPS ASSEMBLY AND MAINTENANCE INSTRUCTIONS SUPPLEMENT ‘M1’ GENERAL INSTRUCTION APPLICABLE TO ALL TYPES OF WARMAN PUMPS

CONTENT 1.

INTRODUCTION

.............................................................................................. 1

General ................................................................................................................ 1 Pump Identification .............................................................................................. 1 2.

FOUNDATIONS

.............................................................................................. 3

Shaft Alignment ................................................................................................... 3 Alignment, Tensioning and Adjustment of Vee-Belt Drives .................................. 3 Alignment of Direct Coupled Pumps .................................................................... 6 Pipework .............................................................................................................. 8 3.

OPERATION

............................................................................................ 10

General .............................................................................................................. 10 Shaft Seal .......................................................................................................... 10 Shaft Unlocking.................................................................................................. 10 Motor Rotation Check ........................................................................................ 11 Priming .............................................................................................................. 11 Normal Pump Start Up ....................................................................................... 11 Abnormal Start Up ............................................................................................. 12 Operating Faults ................................................................................................ 13 Shutting Down Procedure .................................................................................. 14 4.

MAINTENANCE

............................................................................................ 15

Running Maintenance ........................................................................................ 15 Overhaul Maintenance ....................................................................................... 18 5.

COMMISSIONING OF PUMPS ......................................................................... 22 Storage of Pumps & Stand By Pumps ............................................................... 22 Spare Parts........................................................................................................ 22

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – INTRODUCTION

1.

Page 1 of 26

INTRODUCTION GENERAL This Supplement sets out general instructions for the installation, operation and maintenance applicable to all TYPES of Warman Pumps. These instructions should be read in conjunction with the other separate Warman Supplements relating to the assembly and maintenance of the PUMP and BEARING ASSEMBLY pertaining to the particular TYPE of Warman Pump installed. A list of Warman Assembly and Maintenance Instruction Supplements pertaining to Warman pumps is given in Supplement ’M3’.

PUMP IDENTIFICATION Every Warman pump has a nameplate attached to the frame. The pump serial number and identification codes are stamped on the nameplate. The pump identification code is made up of digits and letters arranged as follows:

(a)

DIGITS

LETTERS

LETTERS

(a)

(b)

(c)

PUMP SIZE

FRAME SIZE

WET END TYPE

The PUMP SIZE is expressed in one of the following two ways: 1.

The pump size is taken as the discharge diameter. It is given in millimetres, it is expressed by a number such as 100, 150, 200 etc.

2.

The pump size is given as two numbers separated by a slash viz.: DIGITS (a1)

DIGITS 1

INTAKE DIAMETER

(b)

(a2) DISCHARGE DIAMETER

(i)

The intake diameter is given in inches. It is expressed as a number such as 1, 1.5, 2, 10, etc.

(ii)

The discharge diameter is given in inches. It is expressed as a number such as 1, 1.5, 2, 10, etc. The discharge diameter is usually smaller than the intake diameter, however, in some pumps the two are equal.

The frame of the pump comprises the base and the bearing assembly. The FRAME SIZE of a horizontal pump is identified by either single or multiple Date Issued 14/05/99 Copyright

©

WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – INTRODUCTION

Page 2 of 26

letters viz: Basic frames A to H; Modified Basic frames CC to GG and Heavy Duty frames N to V. The first letter in the range denotes the smallest frame working through the alphabet to the largest frame. Frames with a vertical shaft the letter(s) are followed by a ’V’ Frames that are oil filled the letter(s) are followed by a ’K’ Frames that are oil lubricated the letter(s) are followed by a ’Y’ (c)

The WET END TYPE is identified by one or a multiple of letters. Some of these are: AH, SHD, M, L, SC, HH, H: Slurry pumps with replaceable liners D, G, GH: Dredge and gravel pumps S, SH: Solution pumps TC: Cyklo pumps PC, PCH: Process chemical pumps SP, SPR, GPS: Sump pumps AF: Froth pumps GSL: Flue Gas Desulphurisation pumps High head pumps are generally denoted by a ’H’ at the end of the wet end identification such as in the HH, GH, SH, PCH pump types. High pressure pumps are generally denoted by a ’P’ at the end of the wet end identification such as in the AHP and HP pump types. EXAMPLES: 200 PG-PCH

200 mm discharge diameter PG frame PCH type wet end (high head PC pump)

10/8 FFK-AHP

10 inch intake and 8 inch discharge diameters FF frame (oil filled as denoted by ’K’) AHP type wet end (high pressure AH pump)

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

2.

Page 3 of 26

FOUNDATIONS Efficient pump service can be obtained only by installing the pump on adequate foundations. Steel foundations should be robust, concrete foundations heavy. Both should be designed to take all loads from the pump and motor and to absorb any vibrations. All holding down bolts should be fully tightened. The pump should be located such that the length of the intake pipe is as short as possible. Adequate space to provide access for installation and dismantling to replace worn components should be allowed. A suggested procedure for aligning and grouting Warman Base plates is given on Warman Drawing A3-100-0-19810 attached. Where a pump base is mounted directly onto a steel framework this should be designed with sufficient strength to withstand normal pumping operational stress and to ensure that there is no distortion to the base frame when the pump and pump base are installed.

SHAFT ALIGNMENT Whether direct coupled or vee-belt driven, the pump and motor shafts should be accurately aligned. In direct coupled drives, misalignment causes unnecessary vibration and wear of the coupling. In vee-belt drives, non-parallel shafts cause excessive belt wear. Rigid couplings must be avoided. It should be noted that pump sets which have been accurately aligned in the factory can become misaligned during transportation so alignment must be rechecked during installation. Vee-belt and flexible transmissions should be aligned (and tensioned) in accordance with the suggested recommendations below. Direct coupling large pumps to diesel prime movers must also be avoided as sudden stoppage of the diesel can cause unscrewing of the pump impeller and consequent pump damage. A clutch or fluid coupling fitted between the pump and diesel prime mover is recommended.

ALIGNMENT, TENSIONING AND ADJUSTMENT OF VEE-BELT DRIVES For optimum performance of Vee-Belts, only new matched sets of belts should be used (belts should lie within a range of 2 to 4 set numbers according to the belt length). Always place belts with the lowest code numbers closest to the bearings. Clean any oil or grease from the pulleys and remove any burrs and rust from the grooves before fitting belts.

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 4 of 26

ALIGNMENT Good alignment of pulleys is important, otherwise the belt flanks will wear quickly. Reduce the centre distance by jacking the motor towards the pump using the jacking bolts supplied, until the belts can be put onto the pulley grooves without forcing. Use a good straight edge across both motor and pump pulley faces. It is important to align the two pulleys to a tolerance whereby daylight is non existent or at a minimum between the pulleys and the straight edge. AFTER PUMP IMPELLER ADJUSTMENTS RECHECK PULLEY ALIGNMENT AND ADJUST AS NECESSARY BEFORE RESTARTING PUMP TENSIONING: Proper tensioning of the belts ensures a longer life both for the belts and the roller bearings. The high performance required from modern belts cannot be achieved without correct tensioning. To check the belt for correct tensioning refer to figure below and proceed as follows: (a)

Measure the length of span

(b)

Apply a force at right angles to the belt at the centre of the span sufficient to deflect one belt by 16 mm per metre of span

(c)

Compare the force required with the value stated in the table.

If the measured force is within the values stated in the table the belt tensioning should be satisfactory. If the force measured is below or above the value stated, the belt should be tightened or slackened respectively. Provision should be made for periodic checking of belt wear during the life of a belt and adjusting the belts to correct tension as necessary. NOTE: New belts should be tensioned at the higher level stated (using a Vee-Belt Tension Indicator) to allow for a drop in tension during the normal running in period. New belts should be run under load for two hours, stopped, and the tension re-checked, re-setting the adjustment to achieve the correct tension as necessary. During the first 24 hours running, it is recommended that a further check is carried out and the belts adjusted as required. Under tensioning: Under tensioning of the drive can cause vibration resulting in damage to the bearing cartridge, as well as the loss of transmission efficiency. It can also cause the belts to slip and overheat, resulting in belt fatigue and subsequently a shortening of the belt life. Over tensioning: Over tensioning belts also shortens their life. Furthermore, bearings will tend to overheat due to excessive radial forces on the rolling elements and this will lead to premature bearing failure. Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 5 of 26

ADJUSTMENT After new belts have been fitted or a new installation has been completed, when the drive has been running for approximately 2 hours the tension of the belts should be re-checked and re-adjusted. The drive should be subsequently checked at regular maintenance intervals.

span

16mm deflection per metre of span

Force

Small Pulley Diameter (mm)

Force required to deflect belt 16mm per metre of span; Newton (N)

SPZ

56 to 95 100 to 140

13 to 20 20 to 25

SPA

80 to 132

25 to 35

140 to 200

35 to 45

Belt Section

112 to 224

45 to 65

236 to 315

65 to 85

224 to 355

85 to 115

375 to 560

115 to 150

A

80 to 140

10 to 15

B

125 to 200

20 to 30

C

200 to 400

40 to 60

SPB SPC

Figure 1: Alignment, Tensioning and adjustment of Vee-Belt Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 6 of 26

ALIGNMENT OF DIRECT COUPLED PUMPS In a direct coupled drive, misalignment causes unnecessary vibration and wear on the bearings. Rigid couplings (ie couplings that bolt directly together without any flexible member in between) should be avoided and must not be used without consultation with Warman International. The following procedures outline a suggested practice for checking shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected by canted coupling faces or eccentricity of the outside diameter of the coupling. CAUTION: CHECK THAT NO DAMAGE CAN BE CAUSED WHEN THE SHAFT OF THE DRIVEN UNIT IS TURNED. Before commencing alignment rotate each shaft independently to check that the shaft and bearings turn without undue friction and that the shaft is true to within 0.04 mm or better as measured on a Dial Indicator (DI). Couplings should be loosely coupled, each half must be free to move relative to the other or the resulting Dial Indicator readings can be incorrect. Where tightly fitting pins or springs prevent loose coupling, the pins or springs should be removed, a line scribed across both half couplings and the readings taken only when the two are aligned. On couplings with a serrated rim, ensure that as the couplings are rotated, the gauge plungers do not fall into a groove and become damaged. Angular shaft alignment: To ensure correct angular shaft alignment proceed as follows: (a)

Isolate the driving unit from the power supply.

(b)

Refer to the left hand figure below and clamp two Dial Indicators (DI) at diametrically opposite points (180°) on one half coupling, with the plungers resting on the back of the other half coupling.

(c)

Rotate the couplings until the gauges are in line vertically, and set the gauges to read zero.

(d)

Rotate the couplings through half a revolution (180°) and record the reading on each DI. The readings should be identical though not necessarily zero because of possible end float. Either positive or negative readings are acceptable provided they are equally positive or equally negative. Refer to the paragraphs below headed "Tolerances" for the maximum allowable tolerance and adjust the position of one of the units if necessary.

(e)

Rotate the couplings until the gauges are in line horizontally and reset the gauges to read zero.

(f)

Repeat operation (d) and adjust the unit position until the correct tolerance is achieved and no further adjustment is necessary. Date Issued 14/05/99 Copyright

©

WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 7 of 26

Radial shaft alignment: To ensure that radial shaft alignment is correct proceed as follows: (a)

Clamp a DI to one half coupling or to the shaft, as shown in right hand portion of figure below, with the plunger resting on the rim of the other half coupling.

(b)

Set the gauge to read zero.

(c)

Rotate the couplings and note the reading at each quarter revolution (90°). Any variation in the readings indicates a deviation from alignment and the position of one of the units must be adjusted until the readings at each quarter revolution are identical or within the tolerances given. Refer to paragraphs below headed "Tolerances".

NOTE: Provisional alignment can be carried out with the unit cold, however, where the working temperature of the pump has the effect of raising the centre line of one machine relative to the other allowances must be made. The units should then be realigned when each have attained their correct operating temperature. Tolerances: Follow the manufacturers recommendation. If no recommendation is available the limits of accuracy within which adjustments must be made cannot be specifically defined because of differences in the size of and speed of units. However, the following variations which can be tolerated when checking alignment and are suggested as a general guidance. 1.

Angular Alignment:

Couplings up to 300 mm diameter 0.05 mm Couplings more than 300 mm diameter 0.07 mm 2.

Radial Alignment:

Not to exceed 0.1 mm on Dial Indicator (ie 0.05 mm eccentricity)

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 8 of 26

Figure 2: Alignment of Direct Coupled Pumps

PIPEWORK Pipelines and valves should be properly aligned with pump flanges and they should be supported independently of the pump. All pipe design should be on the basis of zero pump flange loading - if this condition cannot be achieved then values for the maximum allowable external loads and moments on the pump flanges is available from the Head Office of Warman International. APPROPRIATE WARMAN JOINT RINGS (when required) MUST BE USED AT THE PUMP FLANGES. THE JOINT RINGS FORM AN EFFECTIVE SEAL BETWEEN PIPEWORK AND PUMP CASING. In some pumps, the metal liner projects a short distance past the flange. Care should be taken in such instances not to over tighten the flange bolts so as not to damage the joint rings. A removable piece of pipe should be used on the intake side of the pump. This pipe should be of sufficient length to allow removal of the pump cover plate or casing and to enable access to pump wearing parts and impeller. Removal of the intake pipe is facilitated if a flexible joint is used in place of the flanged connection. All pipe joints must be airtight to ensure priming of the pump. Recommendations and procedures for inter-stage piping for multi-stage installations are available from the Head Office of Warman International. Date Issued 14/05/99 Copyright

©

WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – FOUNDATIONS

Page 9 of 26

FLANGES Matching flanges on the pump intake and discharge must be flush as shown on attached drawing A4-111-1-121595. Keeping flanges flush is important in providing proper backup support and compression for intake and discharge joint rings to prevent leakage. Warman Intake and Discharge slip-on matching flanges can be supplied on request. INTAKE CONDITIONS Suitable isolation should be fitted in the intake pipe as near to the pump as possible. The intake pipe should be as short as possible. An arrangement of intake pipework which is common to two or more pumps operating on suction lift is not recommended. If such an arrangement is unavoidable any points of possible air ingress, such as valve glands should be liquid sealed and isolating valves should be fitted at appropriate points. The diameter of the intake pipe required depends upon its length and bears no fixed relationship to the diameter of the intake branch of the pump. The size of the pipe must be such that the velocity is kept to a minimum, but above the solids particle critical settling velocity to reduce friction losses, i.e. a long intake pipe, (or one with numerous bends) which passes a given quantity or liquid must be of larger bore than a short straight one passing the same quantity of liquid. When the bore of the intake pipe is increased to a size larger than that of the pump intake branch, the form of taper pipe used must not allow the formation of air pockets. To avoid air pockets, the installation of intake pipework must be arranged with as few bends as possible and the pipework must be completely airtight.

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – OPERATION

3.

Page 10 of 26

OPERATION GENERAL The principle requirements for operation of Warman pumps are as follows: • • • • • •

Priming arrangements to raise water in the intake pipe and fill the pump. Gland sealing water (on gland sealed pumps) provided at adequate pressure and flow. Impellers adjusted to maintain minimum clearance with front liner. Wearing parts replaced when performance falls below required operating pressure. Volute liner seal and stuffing box seal maintained to prevent leakage. Grease purged labyrinths (where used) lubricated regularly to prolong bearing life by excluding dust and dirt from the bearing assembly.

SHAFT SEAL For gland sealed pumps, check gland water is available and that it is of sufficient quantity and at the correct pressure. Gland water pressure should be approximately 35 kPa above the pump discharge pressure. Gland water pressure should generally not be higher than 200 kPa above the pump discharge pressure, otherwise reduced gland life could result. Slacken off gland and adjust it so that a small flow is obtained along the shaft. Note that pumps supplied directly from Warman factories usually have tight glands to minimise shaft vibration during transport. For centrifugally sealed pumps, screw the grease cup down a few turns to charge the static seal chamber with grease.

SHAFT UNLOCKING For transport of Warman pumps the bearings can be locked to prevent vibration and consequent damage. Note that it is not absolutely critical to lock the bearings as small movements help to prevent false briselling. Clamping is done by attaching the shaft clamp to the shaft. A set screw in the handle of the clamp is then screwed up hard against the pump base to lock the bearings. Alternatively, the pump is supplied with the vee-belts tensioned to reduce shaft movement. Before use of the pump, the set screw must be removed to free the bearings or alternatively the vee-belt tension must be checked and adjusted if necessary. The shaft should then be rotated by hand (clockwise) by means of the clamp to ensure that the impeller turns freely within the pump. At any sign of scraping noises from the pump, the impeller must be adjusted (see Assembly and Maintenance Instructions for the particular TYPE of Warman pump). The shaft clamp must then be removed.

Date Issued 14/05/99 Copyright

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WARMAN INTERNATIONAL LTD

ISSUED: MAY 1999

M1 – OPERATION

Page 11 of 26

MOTOR ROTATION CHECK Remove all vee-belts or completely disconnect shaft coupling, as the case may be. THIS IS IMPORTANT! Start motor, check rotation and correct it if necessary to produce pump shaft rotation indicated by arrow on the pump casing. Refit vee-belts or reconnect shaft coupling. When tensioning belts maintain shaft alignment and check belt tension. WARNING ROTATION IN DIRECTION OPPOSITE TO THE ARROW THE PUMP WILL UNSCREW THE IMPELLER FROM THE SHAFT CAUSING SERIOUS DAMAGE TO THE PUMP

PRIMING Arrangements for raising water in the intake pipe and filling the pump (or first stage of a multi-stage installation) must be provided in preparation to starting up. Gland sealing water should then be turned on to the pump(s). To ensure trouble free operation of glands the gland sealing water pressures should be approximately 35 kPa higher then the pumps operating discharge pressure. IMPORTANT NOTE: Gland sealing water must be left on during all subsequent operations, namely, start up, running, shut down and run back. Gland water may be turned off only after shut down and then only after all the slurry in the pipeline has drained back to the pit.

NORMAL PUMP START UP Check once more that all bolts are tight and that the impeller turns freely. Ensure that shaft seal is in order and that pressure of gland water supply, where used, is correct. It is good practice whenever possible to start up pumps on water before introducing solids or slurry into the stream. On shutting down it is also desirable that pumps should be allowed to pump water only for a short period before shut down. Open intake valve (if any) and check that water is available at the inlet. Check drain valve (if any) is closed. If a discharge valve is installed it is common practice to close it for start up. This is however mandatory only in some special cases where the motor could overload. Start pump and run up to speed, if pump is on suction lift execute priming procedure for facilities provided. When the pump is primed, isolate prime facilities (if any). Open discharge valve. Check intake and discharge pressures (if gauges have been provided). Check flow rate by inspection of meters or pipe discharge. Check Gland leakage. If leakage is excessive tighten gland nuts until flow is reduced to the required level. If leakage is insufficient and gland shows signs of heating, then try loosening gland nuts. If this is ineffective and the gland continues Date Issued 14/05/99 Copyright

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to heat up, the pump should be stopped and the gland allowed to cool. Gland nuts should not be loosened to such an extent that the gland follower is allowed to disengage the stuffing box. NOTE It is normal for gland leakage water to be hotter than the supply because it is conducting away the heat generated by friction in the gland. At low pressures (single stage operation) very little leakage is required and it is possible to operate with only a small amount of water issuing from the gland. It is not essential to stop a pump because of gland heating unless steam or smoke is produced. This difficulty is normally only experienced on initial start up on gland sealed pumps. When initial heat up of the gland is encountered, it is only necessary to start up -- stop -- cool and start the pump two or three times before the packing beds in correctly and the gland operates satisfactorily. It is preferable at start to have too much leakage than not enough. After the pump has run for 8-10 hours, gland bolts can be adjusted to give optimum leakage. If heating of gland persists, the packing should be removed and the gland repacked. Warman pumps are normally packed with non-asbestos packing, Warman material code Q05, for general duties and pressures up to 2000 kPa. Above 2000 kPa it is usually necessary to use an anti-extrusion ring between the gland follower and the last ring of packing. High pressure packing recommendations are available from the Head Office of Warman International. For multi-stage installations it is usually necessary to time the starting of the second and subsequent stage pumps to prevent motor overload. Recommendations and procedures for start up are available from the Head Office of Warman International.

ABNORMAL START UP If the pump fails to prime, one or more of the following faults may be the cause: BLOCKED INTAKE PIPE

When the pump has not been operated for some time, it is possible for slurry to settle in the intake pipe or around it if operating from a pit and thereby prevent water rising to the pump impeller. The pressure gauge on the intake side of the pump may be used to check the level of water in the pump. AIR ENTERING GLAND

If one of the following conditions apply, air may be induced into the pump through the gland. This may prevent the pump "picking up" its prime or cause it to loss its prime during operation. •

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• • •

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Packing is excessively worn Shaft sleeve is excessively worn Gland sealing water connection into stuffing box is blocked.

Inspection of the gland will readily reveal if above faults are occurring and remedial action is self evident.

OPERATING FAULTS Refer to the FAULT FINDING CHART at the back of this Supplement to determine the most likely cause of any problems. Some of the major faults that can occur are more fully detailed below. Overloading can occur when the pump is discharging into an empty system when the delivery head will be temporarily lower and the throughput in excess of that for which the pump is designed. Careful regulation of the delivery valve until the system is fully charged will prevent this. WARNING: PUMPS THAT ARE NOT FITTED WITH A LEAK-OFF DEVICE MUST NOT BE RUN FOR A LONG PERIOD AGAINST A CLOSED DISCHARGE VALVE. LOW PIT LEVEL

Pumps (or first stage pumps in a multi-stage installation) may lose their prime if air is induced through the gland. Pumps may also lose their prime if the water level in the pit falls sufficiently low to allow air to be induced into the pump intake by vortex action. In order to obtain the best possible pump operation, sump (or hopper) makeup water controls should be arranged to maintain as high a level in the sump (or hopper) as runback requirements will allow and should be arranged to maintain this level within as close limits as is practical. BLOCKED INTAKE PIPE

It is possible during operation of pump for a piece of foreign material to be drawn across the bottom of the intake pipe and thereby cause a partial obstruction. Such an obstruction may not be sufficient to stop operation completely but will result in a reduced output from the pump. It will also cause a drop in discharge pressure and amps, and will increase the vacuum reading on the pump intake. Rough running and vibration of the pump may also occur due to the high induced suction causing cavitation within the pump. BLOCKED IMPELLER

Impellers are capable of passing a certain size particle. If a particle larger in size enters the intake pipe it may become lodged in the eye of the impeller thereby restricting the output of the pump. Such an obstruction will usually result in a drop of amps and a drop in both discharge pressure and intake vacuum readings. Pump vibrations will also occur due to the out of balance effects.

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SAFETY WARNING: BEFORE APPLYING MANUAL TORQUE TO THE PUMP SHAFT ENSURE THAT THE INTAKE AND DISCHARGE LINES ARE ISOLATED AND THAT THE MOTOR IS DISCONNECTED. BLOCKED DISCHARGE PIPE

Blocked discharge pipe may be caused by abnormally high concentration of coarse particles in the pump discharge pipe or by the velocity in the discharge pipe being too low to adequately transport the solids. Such a blockage will be shown up by a rise in discharge pressure and a drop in amps and intake vacuum readings.

SHUTTING DOWN PROCEDURE Whenever possible, the pump should be allowed to operate on water only for a short period to clear any slurry through the system before shut down. 1.

Close the discharge valve (if fitted) to reduce load on driving unit

2.

Shut down the pump

3.

Shut intake valve (if any)

4.

If possible flush pump with clean water and let it discharge through the drain valve.

5.

Gland sealing water (if any) must be left on during all subsequent operations, namely: Start up, running, shut down and run back.

Gland water may only then be turned off.

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MAINTENANCE RUNNING MAINTENANCE GENERAL

Warman pumps are of robust construction and when correctly assembled and installed, they will give long trouble-free service with a minimum amount of maintenance. The only maintenance required for pumps in operation is as follows: • • • • •

Gland adjustment Gland re-packing Impeller adjustment Tightening down Possible periodic greasing of Bearings

SHAFT SEAL CARE

Gland The gland sealing water supply should be steady as pressure fluctuations will make gland adjustment for optimum performance difficult. Glands must be adjusted to provide reasonable leakage when seal water pressure is at a minimum and therefore when this pressure rises leakage will necessarily be excessive. If glands are adjusted to provide optimum leakage at the higher seal water pressures, insufficient lubrication will be obtained when this pressure falls. The gland sealing water should be as clean as possible as even small amounts of solids can quickly wear gland components. Refer to recommendations of gland water quality in the respective Gland Maintenance Manuals. Requirements for gland operation on the first stage of a multi-stage installation are different from the other stages. For the second and succeeding stages the gland water is only required to flush slurry away from the shaft sleeve and provide lubrication for the gland packing. Gland water for the first stage pumps as well as carrying out the above functions must also pressurise the gland to prevent ingress of air when the pressure at the shaft falls below atmospheric. Check periodically gland seal water supply and discharge. Always maintain a very small amount of clean water leakage along the shaft by regularly adjusting the gland. When gland adjustment is no longer possible replace all packings with new ones. Gland sealing water requirements can be reduced to a minimum using Warman Low Flow Lantern Restrictors (Warman basic part Nº 118-1).

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Centrifugal In centrifugally sealed pumps lubricate the static seal chamber sparingly but regularly by means of the grease cup. Two turns of the grease cup per 12 hours running time is recommended to form an adequate seal at the packing rings, to lubricate the gland packing and to enable them to run in a dry condition. Use only recommended, clean lubricant. REPACKNG GLAND

When gland packing has deteriorated to such an extent that no further adjustment can be obtained by tightening down the gland follower, it is not good practice to attempt to correct this by inserting one new ring of packing on top of the old rings. When the gland follower has reached the limit of its travel all the old packing should be removed from the gland and the gland repacked with new packing. To repack a gland the gland bolts and gland clamp bolts should be taken out and the two halves of the gland follower removed from the pump. Old packing may then be removed and the stuffing box recess cleaned out. It is not necessary to remove the lantern restrictor during this operation. Rings of new packing should then be placed in position and tamped home one ring at a time, making sure that the ends of each ring come hard together and joints in successive rings are staggered around the stuffing box. Gland halves may then be replaced, secured with clamp bolts and nipped down with gland bolts. Nuts on gland bolts should then be slacked off and left finger tight until pump is started. After start-up glands maybe adjusted until leakage is at the required flow rate. These glands are designed for water lubrication and some leakage is necessary during operation to lubricate and cool the packing and shaft sleeve. Gland leakage at all times must be clean and free from solids. If there is any sign of slurry leaking from a gland then one of the following must be occurring:• • •

Gland sealing water pressure is too low Gland packing and/or shaft sleeve requires replacement Gland sealing water connection to stuffing box is blocked

When a gland is being repacked during a complete pump overhaul it is easier to pack the stuffing box and assemble the gland while the stuffing box is out of the pump (refer to instructions in the particular Warman Instruction Supplement depending on the TYPE of pump). The lantern restrictor, packing and gland maybe assembled into the stuffing box with the shaft sleeve in position in the stuffing box. The stuffing box, assembled gland and shaft sleeve may then be fitted to the pump as one unit. IMPELLER ADJUSTMENT

Warman pump performance changes with the clearance existing between an open Impeller and the intake side liner. This is less pronounced with closed Impellers.

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With wear, the clearance increases and the pump efficiency drops. For best performance it is necessary, therefore, to stop the pump occasionally and move the impeller forward (this applies to metal, rubber and high efficiency style impellers). This adjustment can be carried out in a few minutes without any dismantling. The correct setting of the impeller is when the clearance between the impeller and the intake side liner is a minimum. AFTER PUMP IMPELLER ADJUSTMENTS ALIGNMENT AND ADJUST AS NECESSARY.

RECHECK

PULLEY

TIGHTENING DOWN

Although Warman pump impellers are balanced before they leave the works, precise balance cannot be achieved in operation because of uneven wear which can take place. Pumps are therefore subject to some vibration while running and this can result in loosening of some bolts. It is recommended therefore that a routine maintenance program be established whereby a check be made at regular intervals to ensure that all nuts are tight. To avoid any possible movement between the Bearing Assembly and the Base, the Bearing Housing Clamp Bolt must be maintained fully tightened. (See Table 1) A convenient time for this check to be carried out would be at the same time as impeller adjustment is made. If any location is found where bolts consistently loosen then ’Nylock’ nuts or other suitable locking devices should be fitted. LABYRINTH GREASE PURGING

To improve the sealing properties of the labyrinths on the end covers of some types of Warman bearing assemblies, grease purging is utilised to purge out grit and moisture. Less contaminants entering the bearing assembly will result in longer bearing life and ultimately cost savings. Therefore careful attention paid to labyrinth purging is an essential maintenance requirement. Full details are given in the relevant Warman Bearing Assembly Instruction Supplement. BEARING LUBRICATION

A correctly assembled and pre-greased bearing assembly will have a long trouble free life, provided it is protected against ingress of water or other foreign matter and that it is adequately maintained. Suggested regreasing intervals are tabulated in the relevant “BA” maintenance supplement depending on the type of bearing assembly in use. It must be left to the good judgement of maintenance personnel, to open bearing housings at regular intervals (not longer than twelve months) to inspect bearings and grease, to determinethe effectiveness of the relubrication program and to make any adjustments to the program for the period up to the next inspection. In the case of infrequent bearing regreasing being required, the bearing assembly grease plug can be temporary replaced with grease nipples at the time of greasing.

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If a regular addition of grease is judged to be necessary, then the plugs on the bearing assembly should be replaced with grease nipples. It is preferable to lubricate often and sparingly, than to add large amounts at long intervals. Bearings must never be over greased. Use only recommended, clean grease. For oil lubricated bearings, it is recommended that a full oil change is carried out every 6 months or 4,000 hours. Additional information and recommendations on bearing lubrication intervals are contained in the relevant Warman Bearing Assembly Instruction Supplements and in the following sections 6.2.3 below.

OVERHAUL MAINTENANCE GENERAL

When the pump has worn to such an extent that the performance obtained no longer is satisfactory then the pump(s) should be dismantled for inspection and/or replacement of wearing parts (impeller and liners). If the bearing assembly requires maintenance, then the pump wet end must be dismantled before the bearing assembly can be removed from the pump. NOTE:Bearing assemblies should only be reconditioned in a workshop preferably in a specific area set aside for the work. A clean environment is essential. PUMP DISMANTLING

Isolate the pump from the system and wash down as much as possible. Remove drive items as necessary after noting alignment of drive. Dismantling can be done in situ if suitable lifting facilities and working space are available otherwise the complete pump should be removed to a maintenance workshop. NOTE: (a)

It is recommended that bearing assemblies should only be dismantled and overhauled in the workshop.

(b)

When bearing components are removed from a pump, they should be identified with suitable tags so that if they are reused they may be replaced in the same position in the pump with their correct mating parts.

(c)

Bearing components which are an interference fit on the shaft should be removed only if replacement is necessary.

The procedure for removing the pump or bearing assembly is simply a reversal of the assembly procedure as set out in the relevant Instruction Supplements for the pump and bearing assembly.

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Note that the pump must be dismantled before the bearing assembly can be removed for reconditioning. All Warman pumps utilise a thread to fasten the impeller to the pump shaft. The larger pumps incorporate an impeller release collar to facilitate impeller removal. Full details can be found in Warman Supplement ’M2’. INSPECTION AND REMOVAL OF BEARINGS

Since greasing requirements vary with operating conditions and environment the following general recommendations should be used as a guide. When new bearings are fitted or re-assembled after overhaul they should be correctly packed with grease. It is then recommended that a systematic program of investigation be instituted in order to ascertain the following: • • •

whether the grease addition is required between overhauls how frequently grease addition is required what quantity of grease addition is required.

Proposals regarding the amount and frequency are given in the relevant manual Supplements depending on pump speed. A suggested program of investigation is briefly described below for the case of a number of the same pumps operating on similar or the same duties (i.e. the pumps have identical bearings). (a)

Start with two pumps with bearings correctly packed with grease

(b)

After a set number of hours (depending on the duty and environment) dismantle the bearing assembly of one pump and inspect condition and disposition of the grease

(c)

From inspection assess whether grease addition is required at this interval and if grease addition is not required assess whether the second pump can safely run to twice the set number of hours without greasing

(d)

By repeating this procedure on the remaining pumps in turn, the maximum time interval before re-greasing may be determined and it may be found possible to run pumps for the life of the wearing parts without re-greasing bearings.

If these conditions can be achieved then bearing contamination is avoided and an overall saving in labour effected. It is recommended that a spare bearing assembly unit should be carried in store so that the assembly may be changed over when wearing parts are being replaced. The assembly taken out may then be reconditioned in the workshop ready for installation in the next drive assembly overhaul. With correct care and maintenance, deterioration of bearings should be detected during routine overhauls before malfunctions become obvious in operation.

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The criteria for examination of a bearing is contained in the question "Will the bearing operate until the next overhaul?" Where there is any doubt regarding the condition of a bearing it is far more economical to replace it while the pump is dismantled for overhaul than to risk a failure in operation which may result in damage to other parts of the pump. When to Remove Bearings Bearings should be renewed when any of the following faults are observed: (a)

Face of race is worn to such an extent that a detectable shoulder is evident at the edge of the rolling track

(b)

Cage is worn to such an extent that there is excessive slackness or burrs.

(c)

Any roughness or pitting of rollers or rolling track.

The rolling track will often be slightly darker than the unused portion of the race. This does not mean that the bearing has reached the end of its useful life provided no other symptoms are present. Removing Bearings Care should be exercised during dismantling. When driving bearing cups out of the assembly with shaft and rollers, the shaft should be held hard in the direction of driving so that rollers are seated hard up against the face of the cup and the effects of impact on the bearing faces are thereby minimised. If inspection of bearings shows that they require replacement then a press or suitable puller should be set up to bear on the end of the shaft and on the bearings. When bearing components are removed from an assembly, they should be identified with suitable tags so that if they are reused they maybe replaced in the same position in the assembly with their correct mating parts. If any portion of a bearing required replacing then the bearing should be replaced in its entirety. Worn parts must not be mixed with new parts. A complete new bearing at one end of a bearing assembly may be installed with a used bearing at the other if required; however, if one bearing requires replacement, economics usually favour renewing the pair. REPLACEMENT OF WEARING PARTS

The wear rate of a solids handling pump is a function of the severity of the pumping duty and of the abrasive properties of the material handled. Therefore, the life of wearing parts, such as impellers and liners, varies from pump to pump and from one installation to another. As pump impellers and liners become worn the head developed by the pump decreases. As the head decreases a consequent drop in rate of discharge will occur. When the rate of discharge has fallen to such a level that either the required quantity of slurry cannot be discharged or the line velocity is too low for satisfactory transportation of the slurry then the pump(s) should be dismantled for inspection of impeller and liners. Date Issued 14/05/99 Copyright

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Replacement of the impeller only, will result in the pump regaining almost new pump performance. Whether liners require replacement should be assessed by estimating whether the proportionate thickness remaining will provide reasonable further life before replacement is required. Where a pump is used on a particular duty for the first time and especially where failure of a wearing part during service could have serious consequences, it is recommended that the pump be opened at regular intervals, parts be inspected and their wear rate estimated so that the remaining life of the parts may be established. For installation of new wearing parts refer to relevant Warman Pump Supplement. REASSEMBLING PUMP OVERHAUL

When pumps have been dismantled for complete overhaul all parts should be closely inspected and new parts checked for correct identification. Used parts being replaced should be thoroughly cleaned and painted. Mating faces should be free from rust, dirt and burrs and given a coat of grease before they are fitted together. It is preferable to renew small bolts and set screws during overhaul and all threads should be coated with graphite grease before reassembly. It is recommended that all rubber seals should be replaced during major overhauls as rubber tends to harden and seals lose their effectiveness.

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M1 – COMMISSIONING OF PUMPS

5.

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COMMISSIONING OF PUMPS In addition to the procedures and safety instructions necessary at start up the following checks should be performed at Commissioning:• • •

Impeller clearance is preset for give optimum efficiency but this should be checked and adjusted. Refer to the section on impeller adjustment in this supplement. Grease the labyrinths until grease emerges at the outside. Check bolts and nuts on motor and pump in case some have become loose during transport.

STORAGE OF PUMPS & STAND BY PUMPS Store only clean pumps. Pumps taken out of service should be flushed with water and dried before storage. Indoor storage is recommended especially for elastomer pumps. Too much heat can artificially age elastomer and render it unserviceable. For outside stored pumps it is recommended to cover the unit(s) with a tarpaulin rather than plastic so that air can circulate. It is best to cover flanges. Remove transport clamps and loosen gland to release pressure on the packing. Turn the shaft of the pump a quarter of a turn by hand once per week. In this way all the bearing rollers in turn are made to carry static loads and external vibrations. Ensure that the rust preventing coat of the shaft drive end is maintained.

SPARE PARTS Spare parts for Warman pumps consist in the main of liners, impellers, bearings, shaft sleeves, seals and shaft seal parts. Depending on the expected life of each part, a number of spares of each should be kept in stock to ensure maximum use of the pump. In major plants it is usual to stock an additional bearing assembly for every ten (or less) pumps of the same size. This enables a quick change of the bearing assembly in any one of the pumps. Often this operation is carried out when wearing parts are being replaced. The removed bearing assembly can then be inspected in a workshop, overhauled if required and kept ready for the next pump. In this way damage is prevented and all pumps are always kept in optimum condition with a minimum of down time.

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Table 1: Bearing Housing Clamp Bolt Torque FRAME SIZE

MAXIMUM TORQUE (Nm)

FRAME SIZE

MAXIMUM TORQUE (Nm)

A

20

B

30

N

40

C

45

P

45

D

45

Q

45

E

185

R

185

F

185

S

185

G

325

T

525

H

1500

U

1500

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M1 – COMMISSIONING OF PUMPS

ISSUED: MAY 1999

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Fault Finding Chart

FAULTS

Pump not primed Pump or suction pipe not completely filled with liquid Suction lift too high Insufficient margin between suction pressure and vapour pressure Excessive amount of air or gas in liquid Air pocket in suction line Air leaks into suction line Air leaks into pump through stuffing box Foot valve too small Foot valve partially clogged Inlet of suction pipe insufficiently submerged Blocked suction line Inlet pipe diameter too small or length of inlet pipe too long Speed too low Speed too high Wrong direction of rotation Total head of system higher than design Total head of system lower than design Specific gravity of liquid different from design Viscosity of liquid differs from that for which designed Operation at very low capacity Entrained air in pump. Pump hopper requires baffles Badly installed pipe line or gaskets partly blocking pipe Misalignment Foundations not rigid Shaft bent Rotating part rubbing on stationary part Bearings worn Impeller damaged or worn Casing gasket defective, permitting internal leakage Shaft or shaft sleeves worn or scored at the packing Packing improperly installed Incorrect type of packing for operating conditions Shaft running off-centre because of worn bearings or misalignment Impeller out of balance, resulting in vibration Gland too tight, resulting in no flow of liquid to lubricate packing Foreign matter in impeller Dirt or grit in sealing liquid, leading to scoring shaft sleeve Excessive thrust caused by a mechanical failure inside the pump Excessive amount of lubricant in bearing housing causing high bearing temperature Lack of lubrication Improper installation of bearings Dirt getting into bearings Rusting of bearings due to water getting into housing Expeller worn or blocked Excessive clearance at bottom of stuffing box, forcing packing into pump

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Warman Base plates: Drawing A3-100-0-19810 Suggested Procedure for Aligning and Grouting

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ISSUED: MAY 1999

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Warman Slip-on Matching Flanges: Drawing A4-111-1-121595

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Centrifugal Slurry Pumps

WARMAN ASSEMBLY INSTRUCTIONS MODEL MCR MILL CIRCUIT PUMPS (SIZES 250 THROUGH 650)

Ron Bourgeois / Mike Viken Product Development Manager / Senior Designer

© Weir Minerals North America 2007. Weir Minerals North America is the owner of the Copyright in this document. The document and its text, images, diagrams, data and information it contains must not be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals North America.

Office of origin :

Madison

Reference :

Manual Supplement - MDS12

Date :

4/25/2007

Last Issued:

4/19/2007

Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

SAFETY INFORMATION

!!WARNING!! WARMAN WOULD LIKE TO BRING TO YOUR ATTENTION THE POTENTIAL HAZARD CAUSED BY THE CONTINUED OPERATION OF CENTRIFUGAL PUMPS WHEN THE INTAKE AND DISCHARGE ARE BLOCKED. EXTREME HEAT IS GENERATED AND RESULTS IN VAPORIZATION OF THE ENTRAPPED LIQUID. THIS CAN RESULT IN A LIFE THREATENING EXPLOSION. The operation of centrifugal pumps on slurry applications can increase this potential hazard due to the nature of the material being pumped. The additional hazard believed to be presented by slurry applications stem from the possibility of solids blocking the pump discharge and remaining undetected. This situation has been known in some instances to lead to the intake side of the pump also becoming blocked with solids. The continued operation of the pump under these circumstances can be extremely dangerous. If you have an installation that may be prone to this occurrence, we suggest you adopt measures to prevent this blockage situation

!!GENERAL WARNINGS!! 1. DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS, OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORIZE. Slurry pumps should not be operated at flow less than 25% of the best efficiency point for a given RPM. PERSONAL INJURY AND EQUIPMENT DAMAGE COULD RESULT.

2. The WARMAN PUMP is both a PRESSURE VESSEL and a piece of ROTATING EQUIPMENT. All standard safety precautions for such equipment should be followed before and during installation, operation, and maintenance. 3. UNDER NO CIRCUMSTANCE SHOULD HEAT BE USED TO EXPAND OR CUT AN IMPELLER FROM THE SHAFT. Personal injury and damage to equipment could occur as a result of an explosion. A shaft wrench has been provided to assist impeller removal. In some cases, a release collar has also been provided to assist impeller removal. 4. DRIVER ROTATION MUST BE CHECKED before belts or couplings are connected. Personal injury and damage to equipment could result from operating the pump in the wrong direction. Do not touch rotating members with your hand to establish the direction of rotation. 5. For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable speed drives, etc.), standard safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, and maintenance. 6. A PUMP SUBJECT TO VACUUM MUST BE ISOLATED during maintenance and nonpumping periods. Failure to isolate properly could allow impeller to “free-wheel”, resulting in equipment damage and personal injury. 7. DO NOT OPERATE THE PUMP without properly installed stuffing box, v-belt and coupling guards in place.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

8. DO NOT OPERATE THE PUMP if solids have settled and the rotating element cannot be turned by hand. 9. Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal shock may cause damage to the internal components and rupture the pump casing. 10. Do not start a pump that is rotating in reverse, such as the backward rotation caused by slurry runback. Personal injury and damage to equipment could result. 11. Worn pump components can have sharp or jagged edges. Caution must be taken in handling worn parts to prevent damage to slings or personal injury.

12. For the safety of operating personnel, please note that the information supplied in this manual only applies to the fitting of genuine Warman parts and Warman recommended bearings to Warman pumps. On larger pump models equipped with anti-rotate nuts and cover plate studs it is essential these nuts be fully installed (threaded on) by hand prior to assembly. Personal injury and damage to equipment could result otherwise. 13. Tapped holes (for eyebolts) and lugs (for shackles) on Warman parts are for lifting individual parts only. 14. Some equipment such as gear reducers, motors, and oil lubricated pump bearing assemblies are shipped without lubricating oil. Be certain that oil of the proper grade is filled to the proper level in each piece of equipment before start-up. 15. Do not apply heat to or hardface Warman high chrome components. This can cause cracks, residual stresses, and changes the fracture toughness of the parent material. This may lead to catastrophic failure and could result in personal injury and equipment damage even when operating within recommended speed and pressure limits.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

CONTENT INTRODUCTION Bearing Assembly – Maintenance & Assembly Instructions Parts Identification ASSEMBLY INSTRUCTIONS Frame Assembly Page

Î Fitting Bearing Assembly to Base (250 - 450) --------------------------------------Î Fitting Bearing Assembly to Base (550 and 650) -----------------------------------

6 7

Gland Assembly Î Fitting Impeller Release Collar, Shaft Sleeve, Lantern Restrictor,

and Stuffing Box to Shaft ------------------------------------------------------------------- 8 Pump Assembly Î Installing Frame Plate Liner Insert and Frame Plate Liner (250 – 350) ----------

9

Î Installing Frame Plate Liner Insert and Frame Plate Liner (400 – 650) ---------------------------------

10

Î Fitting Frame Plate to Base -------------------------------------------------------------------

11

Î Fitting Impeller to Shaft and setting Back Gap ------------------------------------------

12

Î Installing Throatbush and Cover Plate Liner into Cover Plate (250 – 350) ------ 13 Î Fitting Cover Plate to Frame Plate (250 – 350) ---------------------------------------- 14 Î Installing Throatbush and Cover Pate Liner into Cover Plate (400 – 650) -------- 15 Î Fitting Cover Plate to Frame Plate (400 – 650) ----------------------------------------- 16 Î Fitting Suction Cover,(400 – 650) Intake Joint and Discharge Joint --------------- 17 Î Setting Impeller to Throatbush clearance ------------------------------------------------- 18 Î Centering Stuffing Box-------------------------------------------------------------------------

19

Î Stuffing Box Assembly-------------------------------------------------------------------------- 20 Î Warman Basic Part Number & Part List------------------------------------------------- 21

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

INTRODUCTION Supplement 'MDS12' should be read in conjunction with the following Warman Assembly and Maintenance Instruction Supplements: M1 - General Instructions applicable to ALL TYPES of Warman Pumps M2 - Impeller Release Collar Plus one of the following depending on TYPE of Bearing Assembly used; BA1 - Heavy Duty (Frames N - U) BA3 – Modified Basic (Frames CC – GG) BA6 - Oil Filled Bearing Assemblies (Suffix ‘Y’). NOTE: The recommended grease for grease lubricated assemblies is Mobil SHC 220 or equivalent. For oil lubricated assemblies the recommended oil is Mobil gear SHC 220 or equivalent. These lubricant requirements supersede those called out in Supplement BA1, BA3 and BA6 and allow for higher temperature operation with reduced chance of viscosity breakdown. This supplement contains step by step illustrated instructions for complete and correct assembly of Warman Rubber Lined Mill Circuit pumps 250 – 650 MCR.

Bearing Assembly - Maintenance & Assembly Instructions The Bearing Assembly is assembled and maintained according to the instructions contained in the respective Warman Supplement BA1, BA3 and BA6 according to the TYPE of Bearing Assembly utilized.

Parts Identification The comment in Warman Bearing Assembly Supplements regarding Warman Basic Numbers incorporated in Warman Part Numbers applies in the same manner to Warman Pump component parts. For full description and part number identification, refer to the appropriate Warman Components Diagram. Names and Basic Numbers are used in assembly instructions in this manual. All relevant Warman Basic Numbers are listed at the end of this supplement. In all correspondence with Weir Minerals, or their representatives, and especially when ordering spare parts, it is advisable to use correct names as well as full part numbers to prevent misunderstandings or wrong deliveries. When in doubt, the pump serial number should be quoted as well.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING BEARING ASSEMBLY TO BASE (REFER TO FIGURE 1 for sizes 250 through 450) NOTE: Apply

1.

2. 3.

4.

5.

an anti-seize lubricant to threads of any bolts, studs or nuts.

Insert ADJUSTING SCREW (001) in BASE (003) from outside back of base. Screw on (1) nut and fully tighten. Fit (2) additional nuts and (2) flat washers, in between nuts, to adjusting screw. These nuts are to be left loose and maximum distance apart to allow bearing housing lug to fit over the adjusting screw. Clean machined cradle supports on base and apply grease. NOTE: Remove any paint that may be present on these machined surfaces. Lower the BEARING ASSEMBLY (005) onto the base. Approximately line up machined surfaces of housing with machined surfaces in base. Check that the bearing housing lug fits over the adjusting screw and is positioned between the washers. Fit CLAMP BOLTS (012) through base from underneath. Position CLAMP WASHERS (011) over the bolts and thread on clamp nuts. NOTE: Tighten (2) “A” side clamp nuts. “A” side nuts are on the left when looking from impeller end. Leave (2) ”B” side nuts snug to maintain alignment but allow for axial movement. Apply anti-seize lubricant to portion of shaft extending from labyrinth at impeller end and the shaft thread to prevent moisture damage to the shaft.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING BEARING ASSEMBLY TO BASE (REFER TO FIGURE 2 for sizes 550 & 650) NOTE: Apply

1.

2.

3.

4.

5.

an anti-seize lubricant to threads of any bolts, studs or nuts.

Insert ADJUSTING SCREW (001) in BASE (003) from outside back of base. Screw on (1) nut and fully tighten. Fit (2) additional nuts and (2) flat washers, in between nuts, to adjusting screw. These nuts are to be left loose and maximum distance apart to allow bearing housing lug to fit over the adjusting screw. Clean out machined grooves in supports and fill with grease using the grease zerks both front and back. Apply grease to the machined bearing housing cradle supports. NOTE: Remove any paint that may be present on these machined surfaces. Lower the BEARING ASSEMBLY (005) onto the base. Approximately line up machined surfaces of housing with machined surfaces in base. Check that the bearing housing lug fits over the adjusting screw and is positioned between the washers. Fit CLAMP BOLTS (012) through base from underneath. Position CLAMP PAD (011) over the bolts and thread on (6) clamp pad nuts. NOTE: Tighten (3) “A” side clamp bolts. “A” side bolts are on the left when looking from impeller end. Leave (3) ”B” side bolts snug to maintain alignment but allow for axial movement. Apply anti-seize lubricant to portion of shaft extending from labyrinth at impeller end and the shaft thread to prevent moisture damage to the shaft.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING IMPELLER RELEASE COLLAR, SHAFT SLEEVE, LANTERN RESTRICTOR AND STUFFING BOX TO SHAFT (REFER TO FIGURE 3) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

2.

3.

4.

Fit the IMPELLER RELEASE COLLAR O-RING (109) over the SHAFT (073) and slide it back until it seats in the groove in LABYRINTH (062). Install impeller release collar over the shaft and slide it back to the labyrinth capturing the o-ring. Make sure the mating tapers on both parts match. Position the metal ring over the outer diameter of the impeller release collar and tighten the setscrews. NOTE: Fill the recesses of the set screws and pusher holes with silicone or other suitable sealant to prevent moisture from contacting these fasteners and damaging the threads (Instructions for fitting the impeller release collars are also contained in Warman supplement ‘M2’). Fit (1) SHAFT SLEEVE O-RING (109) over shaft and slide it up to the impeller release collar. For pump models 550 and 650 thread the SHAFT SLEEVE ASSEMBLY GUIDE (330) into the end of the shaft. Disregard this tool for all other models. Position the SHAFT SLEEVE (078) over the guide/shaft and slide it back until contacting the impeller release collar capturing the o-ring. Remove the guide tool, if necessary, and fit second SHAFT SLEEVE O-RING (109) into groove in shaft sleeve. Install LANTERN RESTRICTOR (118) over shaft sleeve in orientation shown in Figure 2 Detail A. (i.e. radial flush holes facing release collar) and slide it as far back on the shaft as possible. NOTE: Make sure the two shoulder bolts are tight. Slide STUFFING BOX (078) onto shaft sleeve and slide it back until the lantern restrictor is inside the stuffing box bore.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

INSTALLING FRAME PLATE LINER INSERT AND FRAME PLATE LINER (REFER TO FIGURE 4 for sizes 250 through 350) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Strap the FRAME PLATE LINER INSERT (041) (FPLI) as shown in Figure 4 Detail A and lower it onto FPLI tool. Lift the FPLI and install FPLI puller studs into tapped holes in FPLI reinforcement. NOTE: FPLI tools with square tops are designed for FPLI only.

2.

Place the FRAME PLATE bowl up on the ground and lower the FPLI onto the frame plate as shown in Figure 4 Detail B. Install a washer and nut to the FPLI puller studs from underneath the frame plate and tighten to the torque specified in Table 1.

3.

Install Frame Plate Liner studs into tapped holes in liner reinforcement. Strap the FRAME PLATE LINER (043) as shown in Figure 4 Detail C and lower it into the FRAME PLATE. Install a washer and nut to the liner studs from underneath the frame plate and tighten to the torque specified in Table 1.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

INSTALLING FRAME PLATE LINER INSERT AND FRAME PLATE LINER (REFER TO FIGURE 5 for sizes 400 through 650) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Strap the FRAME PLATE LINER INSERT (041) (FPLI) as shown in Figure 5 Detail A and lower it onto FPLI tool. Lift the FPLI and install FPLI puller studs into tapped holes in FPLI reinforcement. NOTE: FPLI tools with square tops are designed for FPLI only. The 450 tool (rounded top) is used on the FPLI and the throatbush.

2.

Place the FRAME PLATE bowl up on the floor and lower the FPLI onto the Frame Plate as shown in Figure 5 Detail B. Install a washer and nut to the FPLI pullers studs from underneath the Frame Plate and tighten to the torque specified in Table 1.

3.

Place FRAME PLATE LINER (043) bowl down on the floor. Install Frame Plate Liner Studs into tapped holes in reinforcement. Using a three point pick lift FRAME PLATE as shown in Figure 5 Detail C and lower it onto the FRAME PLATE LINER (043). Install a washer and nut to the Frame Plate Liner Studs and tighten to the torque specified in Table 1.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING FRAME PLATE TO BASE (REFER TO FIGURE 6) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1. Using a two point pick lift the Frame Plate sub-assembly to the vertical position as shown. Thread the FRAME PLATE STUDS (039) into the frame plate and fully tighten. NOTE: Apply anti-seize lubricant to the raised diameter portion of the frame plate studs and the pilot diameter of the frame plate to assist in future disassembly. Remove any paint that may be present on these machined surfaces. Slowly move the sub-assembly towards the base being careful to line up the studs with the holes in the base. Make certain that the pilot in the frame plate has engaged the recess in the base. Install a hex nut to the studs and tighten to the torque specified in Table 2. 2. Install the Pusher Bolts into the tapped holes in the Frame Plate and tighten to 35 N-m (25 ft-lbs).

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING IMPELLER TO SHAFT AND SETTING BACK GAP (REFER TO FIGURE 3 AND 7) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

2.

3.

4.

5.

6. 7.

Fit SHAFT KEY (070) in keyway and bolt SHAFT WRENCH (306) onto shaft as shown in Figure 3. NOTE: Check that clamp bolts on “B” side (i.e. on the right when looking from impeller end) are just tight enough to hold the bearing assembly horizontal but not lock it down. Loosen the FPLI puller stud nuts about 10 mm. Using the Pusher Bolts adjust the FPLI so it is flush with the FRAME PLATE LINER (043) as shown in Detail A. Now tighten the FPLI stud nuts and torque to the values specified on Table 1 in Figure 4. Place IMPELLER on a solid flat surface hub side down. Clamp IMPELLER LIFTING BEAM (313) to impeller using the adjusting screw *1. NOTE: Max. torque on adjusting nut is 70 N-m (50 ft-lbs.) Lift the impeller to vertical position and apply anti-seize lubricant to the threads. NOTE: Check that the impeller release collar, shaft sleeve and o-rings are still in place before proceeding. Align impeller hub with shaft thread and turn shaft by means of the shaft wrench to screw into impeller. With the impeller lifting beam still in place, firmly strike the shaft wrench several times to seat the impeller against the shaft sleeve. Remove lifting beam from impeller by adjusting the lower wedge upward and lowering beam out of impeller eye. Using the Axial Adjusting Nuts move the bearing assembly back until the impeller is flush with frame plate liner insert. Set the “BACK GAP” according to the pump size in Table 3 by offsetting the front axial adjusting nut and washer as shown in Detail B. Move the bearing assembly forward until the lug hits the offset washer and nut. Torque the clamp bolts to the torque specified in Table 4.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

INSTALLING THROATBUSH AND COVER PLATE LINER INTO COVER PLATE (REFER TO FIGURE 8 for sizes 250 through 350) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Strap the THROATBUSH (083) as shown in Figure 8 Detail A and lower it onto the lifting tool. Lift the throatbush and install throatbush puller studs and fully tighten.

2.

Place the COVER PLATE (013) bowl up on a flat solid surface and lower the throatbush into the Cover Plate as shown in Figure 8 Detail B. Install a washer and nut to the puller studs from underneath the Cover Plate and tighten to the torque specified on Table 1.

3.

Install Cover Plate Liner studs and tighten. Strap the COVER PLATE LINER (018) as shown in Figure 8 Detail C and lower it into the COVER PLATE and around the Throatbush. Install a washer and nut to the liner studs from underneath the cover plate and torque to the values specified on Table 1.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING COVER PLATE TO FRAME PLATE (REFER TO FIGURE 9 for sizes 250 through 350) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Install ALIGNMENT PINS (489) in the FRAME PLATE based on your discharge position. NOTE: See component diagram drawing for the location designation of the Alignment Pins.

2.

Using a two point pick lift the Cover Plate sub-assembly to the vertical position as shown and install the Throatbush pusher bolts until hand tight.

3.

Slowly move the COVER PLATE toward the Frame Plate carefully lining up the Casing Alignment Pins. Insert the Cover Plate Bolts from the front of the Cover Plate as shown. Install a hex nut to each Cover Plate Bolt. NOTE: On some models the Cut-Water Bolt may be larger than the Cover Plate Bolts. Tighten to the torque specified in Table 5.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

INSTALLING THROATBUSH TO SUCTION COVER AND COVER PLATE LINER INTO COVER PLATE (REFER TO FIGURE 10 for sizes 400 through 650) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts.

1.

Strap the THROATBUSH (083) as shown in Figure 10 Detail A and lower it onto the lifting tool. Lift the throatbush and install throatbush puller studs and fully tighten.

2.

Place the SUCTION COVER (190) flange down on a flat solid surface and lower the throatbush onto the Suction Cover as shown in Figure 10 Detail B. Install a washer and nut to the puller studs from underneath the Suction Cover and tighten to the torque specified on Table 1.

3.

Place COVER PLATE LINER (018) bowl down on floor. Install Cover Plate Liner studs and tighten. Using a three point pick lift COVER PLATE as shown in Figure 10 Detail C and lower it onto the COVER PLATE LINER (018). Install a washer and nut to the frame plate liner studs and torque to the values specified on Table 1.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING COVER PLATE TO FRAME PLATE (REFER TO FIGURE 11 for sizes 400 through 650) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Install ALIGNMENT PINS (489) in the FRAME PLATE based on your discharge position. NOTE: See component diagram drawing for the location designation of the Alignment Pins.

2.

Assemble ANTI-ROTATION NUTS (284) by hand fully onto COVER PLATE STUDS (015).

3.

Using a two point pick lift the Cover Plate sub-assembly to the vertical position as shown. Install the Suction Cover Studs into the tapped holes and fully tighten. Slowly move the COVER PLATE toward the Frame Plate carefully lining up the Casing Alignment Pins.

4.

Insert the Cover Plate Stud with the Anti-Rotation nut assembled from the back of Frame Plate as shown. Install a washer and nut to each Cover Plate Stud. Thread nuts on fully by hand before using impact wrench. NOTE: On some models the Cut-Water Stud may be larger than the Cover Plate Studs) Tighten the nuts to the torque specified in Table 5.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

FITTING SUCTION COVER, INTAKE JOINT AND DISCHARGE JOINT (REFER TO FIGURE 12 for sizes 400 through 650) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

2.

3.

4.

Turn the Suction Cover sub-assembly over and bolt on the SUCTION COVER LIFTING BEAM (309) NOTE: Some suction cover lifting beams may be common to more than one pump size. Refer to nameplate on lifting beam. Lift the Suction Cover to the vertical position and install the Throatbush Pusher Bolts until hand tight. Slowly move the sub-assembly towards the Cover Plate being careful to line up the studs with the holes in the Suction Cover. Fit a washer and nut to each of the suction cover studs and tighten to the torque specified in Table 6. Remove the SUCTION COVER LIFTING BEAM (309) and store for future disassembly. Steps 3 and 4 are common to sizes 250 through 650. Apply a coating of liquid soap (or equivalent) to the INTAKE JOINT RING (372) diameter with seal beads. Push the seal flange in the throatbush until it is seated against the cover. NOTE: Use a block of wood and rubber hammer to help install the Intake Joint Ring. Do not hammer directly on the intake joint as it may distort the reinforcing plate of the seal. Apply a thin coat of silicone to the DISCHARGE JOINT RING (132) and press into place on top of the discharge flange.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

SETTING IMPELLER TO THROATBUSH CLEARANCE (REFER TO FIGURE 13) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Back the throatbush puller stud nuts off about 10 mm to allow the throatbush to move towards the impeller.

2.

While slowly rotating the impeller clockwise with the shaft wrench, tighten the Pusher Bolts in equal amounts until the impeller just starts to rub the throatbush. NOTE: It should still be possible to turn the impeller completely by hand when it starts to rub on the throatbush. Do not adjust the throatbush any further against the impeller. Check the clearance with feeler gauges to verify it is uniform.

3.

Back each of the pusher bolts off by one fourth of a turn (one and a half flats of nut). NOTE: It is recommended to put a mark on one flat of each bolt to keep track of its original position.

4.

Lock the throatbush in place by tightening the throatbush puller stud nuts to the torque specified on Table 1 in Figure 4. NOTE: Check the clearance with feeler gauges to verify it is uniform. Check to make sure the Pusher Bolts are tight to 35 N-m (25 ft-lbs). NOTE: Before removing the shaft wrench make certain the impeller turns freely. The impeller to throatbush clearance should now be set to 1 mm at front seal face.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

CENTERING STUFFING BOX (REFER TO FIGURE 14) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts.

***Centering of the stuffing box is an essential step in the assembly of the pump, it assures that the stuffing box and the shaft sleeve are concentric to each other, thus extending the life of all components contained within the stuffing box. 1.

Slide the stuffing box forward lining up the tapped holes in frame plate liner insert with holes in stuffing box. Place a washer and a bolt in stuffing box holes and hand tighten. NOTE: It may be necessary to lift the stuffing box up slightly to align holes. Slide the LANTERN RESTRICTOR (118) into the bottom of the stuffing box bore. See Figure 2 Detail A for orientation.

2.

Position the STUFFING BOX CENTERING TOOL (331) over the shaft sleeve and slide the tool in the stuffing box bore as shown in Figure 14. NOTE: The three alignment pins should be able to rotate. Fully tighten each of the stuffing box bolts to the torque specified in Table 7. NOTE: Tighten the nuts at the bottom of the stuffing box first.

3.

The stuffing box is now concentrically located about the shaft sleeve. Remove the stuffing box centering tool and store for a future re-build event. Jackscrew holes on centering tool may need to be used to help with removal.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

STUFFING BOX ASSEMBLY (REFER TO FIGURE 15) NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts. 1.

Fit (1) PACKING RING (111) around shaft sleeve and push into the bottom of the stuffing box. NOTE: Install packing rings with the red dots either against the shaft or on the outside as shown in Detail A.

2.

Repeat step 1 with (3) additional packing rings. NOTE: Stagger packing joints 180 degrees.

3.

Assemble the two piece GLAND (044) around the shaft sleeve. Install the GLAND BOLTS and tighten only enough to assure packing is seated in the stuffing box bore. NOTE: The gland bolts should be backed off and hand tight for start-up.

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Weir Minerals | PUMP ASSEMBLY INSTRUCTIONS FOR MODEL MCR (Sizes 250 through 650)

WARMAN BASIC PART NUMBER AND PARTS LIST BASIC PART NUMBER 001 003 004 005 008 009 009D 011 012 013 013-1 015 024 025 027 032 039 041 044 045 061 062 070 073 076 078 083 092 109 111 118 132 145 147 190 221 239 257 284 372 394 394-1 395 489

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Adjusting Screw PUMP ASSEMBY TOOLS Base Bearing Housing 306 Shaft Wrench Bearing Assembly 313 Impeller Lifting Beam Bearing Sleeve 318 Frame Plate Liner Insert / Throatbush Lifting Tool Bearing 330 Shaft Sleeve Assembly Guide Bearing (Drive End) 331 Stuffing Box Centering Tool Clamp Pad / Washer Clamp Bolt Cover Plate Cover Plate (two piece cover) Cover Plate Bolts / Studs End Cover Shim Set End Cover Set Screw Frame Plate Frame Plate Stud Frame Plate Liner Insert Gland Gland Bolt Labyrinth Locknut Labyrinth Shaft Key Shaft Shaft Sleeve Stuffing Box Throatbush Casing Shaft Sleeve O-Ring Packing Lantern Restrictor Discharge Joint Ring Impeller – 4 Vane Closed Impeller – 5 Vane Closed Suction Cover Discharge Flange Impeller Release Collar Discharge Joint Ring Anti Rotation Nuts Intake Joint Ring Cover Plate Reverse Rotation Cover Plate Reverse Rotation (two piece cover) Frame Plate Reverse Rotation Alignment Pin

© Copyright Weir Minerals North America. 2007

Page 21 of 21

Centrifugal Slurry Pumps 2701 S Stoughton Rd PO Box 7610 Madison WI 53716 USA

Tel: +1 608 221 2261 Fax: +1 608 221 5810 www.weirminerals.com

WARMAN ‘M’ STYLE BEARING ASSEMBLY INSTRUCTIONS GREASE LUBRICATED (SIZES M100, M120, M150, M180, M200 & M240)

Ron Bourgeois / Mike Viken Product Development Manager / Senior Designer

© Weir Minerals North America 2009. Weir Minerals North America is the owner of the Copyright in this document. The document and its text, images, diagrams, data and information it contains must not be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Weir Minerals North America.

Office of origin :

Weir Minerals North America

Reference :

Manual Supplement - MDS14

Date :

02/07/2009

Last Issued:

Revision A

Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

BEARING ASSEMBLY-GREASE FOR ‘M’ STYLE BEARING ASSEMBLIES (SIZES M100 thru M240) NOTE: The recommended grease for grease lubricated assemblies is Mobil SHC 220 or equivalent. These lubricant requirements allow for higher temperature operation with reduced chance of viscosity breakdown. This section contains information for bearing assembly designs as indicated above. The pump bearing configuration consists of a double-tapered roller bearing on the drive end and a cylindrical roller bearing on the impeller end of the bearing assembly.

IMPORTANT Read before beginning any bearing assembly work. GENERAL NOTES

When you install new bearings, clean bearing housing, end covers, shaft, etc. so that no foreign material or old grease is present on the parts. Do not wash off factory applied bearing lubricant. The manufacturer uses a high grade non-acid lubrication, free from all chemicals and impurities that might cause corrosion. Any lubricant that you add must be absolutely clean. To assure this, the following procedures are recommended. 1.

Always keep cover on grease can so that no dirt can enter.

2.

Be assured the instrument with which you take grease from can is clean. Avoid using a wooden paddle. Use a steel blade or putty knife that can be wiped off smooth and clean.

3.

In cases where a grease gun is used to introduce grease into bearing chamber, observe the same caution regarding cleanliness of the gun – especially nozzle and grease fittings.

4. Initial grease quantities shown in Table 1 on Page 6 may need to be revised based on observations made during normal operation. For reference purposes, one shot from a standard grease gun is approximately one gram. 5. Lubricate all O-rings with vacuum grease like Dow Corning 111 or equivalent. ROLLER BEARING CLEANLINESS

More than 90% of all roller bearing failures are due to dirt that has found its way into the bearing, either due to carelessness before or during assembly or by the user after unit has been placed in operation. The critical period in bearing life occurs when it leaves the stockroom for the assembly bench, because it is going to be removed from its box and protective covering. When handling bearings it is very important to have clean hands and clean tools. Keep plenty of clean rags available and use them often. Don’t use waste paper, as the lint and short strands adhere readily to oily surfaces. Keep hands and work area wiped clean.

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© Copyright Weir Slurry Group Inc. 2009

MDS14

Page 2 of 12

Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

INSTALLING TAPERED ROLLER BEARING and CYLINDRICAL ROLLER BEARING INNER RACE TO SHAFT (SIZES M100, M120, M150, M180 & M200) Refer to Figures 1-1, 1-2 & 1-3 ! CAUTION !

Tapered Roller Bearings are provided with spacers and as such are pre-set assemblies. Spacers are finished to size for each bearing assembly and are not interchangeable with a similar assembly. In some large bearing assemblies, to aid in correct identification, a “serial number” is marked on each cup, cone and spacer. Components with same “serial numbers” must be kept together. Small pre-set assemblies may not be marked as such but they are still not interchangeable. Bearing component parts should be assembled as received. Failure to comply may result in damage to equipment. It is advisable to preheat Bearing Cones before installation. It is suggested a bearing induction heater is used following the manufacturer’s recommendations. The induction heating method is simple, quick, safe and economical. Before assembly, all parts should be thoroughly cleaned, deburred and sharp edges removed.

FITTING TAPERED ROLLER BEARING and CYLINDRICAL ROLLER BEARING INNER RACE TO SHAFTFOR SIZES M100 thru M200

1. Place Tapered Roller Bearing on induction heater and heat to 250°F (121°C). 2. Apply a light coat of oil to bearing lands on Shaft (073) RH (254) LH.

With shaft on horizontal position, heated bearing can be slipped on and held against shoulder of shaft. 3. Install Tapered Roller Bearing Assembly onto Shaft :

a. The first Cone is placed onto Shaft with taper pointing toward drive end of Shaft. Quickly slide Cone down Shaft until it seats against shoulder on Shaft. b. Next place Cone Spacer on Shaft and slide down until it contacts Cone. (It is not necessary to heat Cone Spacer as it has a slip fit on Shaft). The Cup can be one piece or two Cups and a Cup Spacer. c. Now place Cup on Shaft and slide down until it seats on Cone. d. Place second Cone on Shaft with taper pointing toward impeller end of Shaft. Quickly slide Cone down Shaft until it seats with Cup and Spacer(s). 02/07/2009

© Copyright Weir Slurry Group Inc. 2009

MDS14

Page 3 of 12

Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

NOTE

It is important that bearings are located hard against shaft shoulders and sleeves hard against bearings. This should be further checked after bearings have cooled. 4.

For M100 thru M180 refer to Figure 1-2: Assemble bearing locking assembly components onto shaft and tighten Bearing Locknut with a spanner wrench. Allow Bearing to cool to the touch and retighten Bearing Locknut. Tighten Bearing Locknut until firmly seated and one of the tangs of Bearing Lockwasher can be bent into the slot on Bearing Locknut. Bend Bearing Lockwasher tang into slot. For M200 refer to Figure 1-3: Assemble Bearing Nut (090) onto shaft with tapped holes facing the drive end, tighten by striking the end of a flat bar inserted into the slots with a hammer. Allow Bearing to cool to the touch and retighten Bearing Nut. Tighten Bearing Nut until firmly seated and one of the Bearing Nut Lockplate (506) tabs can be inserted into the keyway and the two holes align with tapped holes in the Bearing Nut. Insert two hex head screws and tighten as shown in Figure 1-3 Detail A. NOTE: The Bearing Nut Lockplate (506) is designed to utilize either tang by flipping and rotating the Bearing Lockplate. ! CAUTION! Never loosen the Bearing Locknut or the Bearing Nut to align the tang or lockplate. Always continue to tighten the nuts to achieve alignment of the tang or lockplate.

5. Place Cylindrical Roller Bearing Inner Race on induction heater and heat to 250°F (121°C). 6. Slide Cylindrical Roller Bearing Inner Race against shaft shoulder.

BEARING LOCKING ASSEMBLY FOR SIZE M100 thru M180

BEARING LOCKING ASSEMBLY FOR SIZE M200 and M240 02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

INSTALLING GREASE RETAINERS, TAPERED ROLLER BEARING and CYLINDRICAL ROLLER BEARING INNER RACE TO SHAFT (SIZE M240) Refer to Figures 1-3 & 1-4 Before assembly, all parts should be thoroughly cleaned, deburred and sharp edges removed.

FITTING GREASE RETAINERS, TAPERED ROLLER BEARING and CYLINDRICAL ROLLER BEARING INNER RACE TO SHAFT FOR SIZE M240 1. Place shaft on assembly jig as shown in Detail B on Page 6. Apply a light coat of oil to bearing lands on Shaft (073) RH (254) LH. 2. Assemble Drive End Grease Retainer (046D). NOTE: Large diameter of flange goes onto the shaft first and must be facing the impeller end of the shaft as shown in Figure 1-4. 3. Place Tapered Roller Bearing on induction heater and heat to 250°F (121°C). With shaft on horizontal position, heated bearing can be slipped on and held against shoulder of Grease Retainer. 4. Install Tapered Roller Bearing Assembly onto Shaft : a. The first Cone is placed onto Shaft with taper pointing toward drive end of Shaft. Quickly slide Cone down Shaft until it seats against shoulder on Grease Retainer. b. Next place Cone Spacer on Shaft and slide down until it contacts Cone. (It is not necessary to heat Cone Spacer as it has a slip fit on Shaft). The Cup can be one piece or two Cups and a Cup Spacer. c. Now place Cup on Shaft and slide down until it seats on Cone. d. Place second Cone on Shaft with taper pointing toward impeller end of Shaft. Quickly slide Cone down Shaft until it seats with Cup and Spacer(s). NOTE

It is important that bearings are located hard against shaft shoulders and sleeves hard against bearings. This should be further checked after bearings have cooled. 02/07/2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

5. For M240 refer to Figure 1-3. Assemble Bearing Nut (090) onto shaft with tapped holes facing the drive end, tighten by striking the end of a flat bar inserted into the slots with a hammer. Allow Bearing to cool to the touch and retighten Bearing Nut. Tighten Bearing Nut until firmly seated and one of the Bearing Nut Lockplate (506) tabs can be inserted into the keyway and the two holes align with tapped holes in the Bearing Nut. Insert two hex head screws and tighten as shown in Figure 1-3 Detail A. NOTE: The Bearing Nut Lockplate (506) is designed to utilize either tang by flipping and rotating the Bearing Lockplate. ! CAUTION! Never loosen the Bearing Locknut or the Bearing Nut to align the tang or lockplate. Always continue to tighten the nuts to achieve alignment of the tang or lockplate. 6. Assemble Impeller End Grease Retainer (046). NOTE: Large diameter of flange goes onto the shaft first and must be facing the drive end of the shaft as shown in Figure 1-4. 7. Place Cylindrical Roller Bearing Inner Race on induction heater and heat to 250°F (121°C). 8. Slide Cylindrical Roller Bearing Inner Race against Grease Retainer shoulder.

NOTE: ONE SHOT FROM A STANDARD GREASE GUN IS APPROXIMATELY ONE GRAM

02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

INSTALLING CYLINDRICAL ROLLER BEARING OUTER RACE and IMPELLER END COVER (SIZES M100 thru M240) Refer to Figure 1-5 1. Clean bearing land surfaces inside of Bearing Housing (004) and apply a light coat of oil. 2. Apply grease behind the bearing See Figure 1-5. Place Cylindrical Roller Bearing Outer Race and Roller Assembly into Bearing Housing. 3. Liberally pack Cylindrical Roller Bearing Outer Race and Roller Assembly with grease. See initial Bearing Grease Quantities in Table 1 on page 6. 4. Install End Cover O-Ring and End Cover (023) on Impeller end of Bearing Housing with eight End Cover Hex Bolts. Tighten bolts using criss cross method to values shown in Table 1 Figure 1-5 for specific bearing assembly size.

FITTING CYLINDRICAL ROLLER BEARING OUTER RACE, and IMPELLER END COVER FOR SIZE M100 thru M240

02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

INSTALLING SHAFT ASSEMBLY, DRIVE END COVER and DRIVE END BEARING ISOLATOR (SIZES M100 thru M240) Figure 1-6 1. Rotate Bearing Housing (004) to vertical position with drive end facing up. Apply grease behind bearing into bearing housing. Liberally pack Tapered Roller Bearing with grease initially using the radial holes in the Cup Spacer and then between the rollers as shown in Figure 1-6. For M240 apply grease to small diameters of the both Grease Retainers as shown in Figure 1-4. See Initial Bearing Grease Quantities in Table 1 on page 6. 2. Using the tapped hole in the drive end of shaft slowly lower Shaft Assembly into Bearing Housing until the Tapered Roller Bearing engages housing. Continue to lower the assembly until Tapered Roller Bearing has become seated in Bearing Housing. 3. Install End Cover O-ring and End Cover (024) on Drive end of Bearing Housing with eight End Cover Bolts. Tighten bolts using criss cross method to values shown in Table 2 Figure 1-5 for specific bearing assembly size. 4. Depending on bearing assembly size install Bearing Isolator (482D) into End Cover (024) orientated as shown in Detail C or Detail D in Figure 1-6. NOTE: Models M200 and M240 Bearing Isolators are bolted into the end cover. IMPORTANT: Drain port of Bearing Isolator must be at the 6 O’clock bottom position. The colored dot should be at the 12 O’clock top position. *** Use this instruction for the Impeller End Bearing Isolator installation also. Rotate Bearing Assembly to horizontal position.

02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

INSTALLING RELEASE COLLAR ASSEMBLY and IMPELLER END BEARING ISOLATOR (SIZES M100 thru M240) Figure 1-6, 1-7 & 1-8

NOTE Before assembly, all parts should be thoroughly cleaned, deburred and sharp edges removed. NOTE: Refer to Figure 1-8 for detailed section view of the following procedure. 1. Apply anti-seize to bearing Shaft (073) RH (254) LH. 2. Install Impeller End Bearing Isolator (482) into End Cover (023). Refer to Figure 1-6 & 1-7. 3. Lubricate the outer surface of the Flinger sleeve with vacuum grease to allow it to slide under the Bearing Isolator O-rings. Install Flinger (184) over shaft and press into place under Bearing Isolator until it is tight against the bearing inner race. 4. Place Release Collar Segments around Shaft with matching letter faces touching as shown in Figure 1-7 Detail E. Stretch Release Collar Wedge O-Ring around segments. NOTE: By design this O-ring requires a large amount of stretch to fit around the segments. This is required to hold the segments together during assembly. 5. Liberally coat Release Collar Wedge Set (239A) with grease including between Segments. Coat the inside surface of the Release Collar Cover (239B) including the tapped holes. 6. Slide Release Collar Wedge Set against Flinger. Ensure tapered face of Release Collar Wedge Set matches tapered face of Flinger. 7. Install the Release Collar Cover O-Ring into Release Collar Cover. 8. Make sure that the set screws in the Release Collar Cover straddle each wedge equally. Depending on the bearing assembly size, two or three set screws are required for each wedge. This will ensure each wedge will receive a uniform load when the set screws are tightened. Refer to Figure 1-7 Detail F. 9. Slide the Release Collar Cover groove end first over the wedges making sure the O-Ring remains in place. Push the collar cover against the flinger until the cover slides under the rubber lip on the flinger and snaps into place. 10. Slide the pump Shaft Sleeve (076) on the Shaft, tapered edge first, until it slides past the Release Collar Cover O-Ring and seats against the wedges. Note: It is critical that the shaft sleeve be installed on the shaft with the smallest diameter or the end with a groove towards the release collar or the wedges will not reset properly. NOTE

If Shaft Sleeve will not slide easily under Release Collar Cover O-Ring, apply a small amount of vacuum grease to end of Sleeve and gently tap into place with a rubber mallet. 11. Evenly tighten the Flat Point Set Screws one-half (1/2) turn at a time in sequence until they evenly contact Release Collar wedge segments. Tighten to 5-10 ft-lbs (7-14 N•m). 12. Cover each Set Screw with RTV silicone or other suitable sealant to protect threads during pump operation.

02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

FITTING RELEASE COLLAR ASSEMBLY and IMPELLER END BEARING ISOLATOR FOR SIZE M100 thru M240

02/07/2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

RELEASE COLLAR REMOVAL (SIZES M100 thru M240) ! CAUTION ! Do not apply heat to or attempt to cut segments from shaft. Heat may damage bearing or shaft. 1. Remove sealant and any other foreign material from Set Screws. Ensure full engagement of Allen wrench into socket heads. 2. Loosen each Set Screw in sequence one-quarter (1/4) turn at a time until segments “release” and screws rotate freely. Rotating shaft allows easier access while loosening Set Screws. DO NOT remove Set Screws. NOTE: Failure to gradually release Set Screws will result in damage to Release Collar wedge segments. If first Set Screw is loose on second pass, segments HAVE NOT been released. To release segments, remove loose Set Screw and replace with fully threaded machine screw, finger tight against segment. Strike machine screw with hammer, then remove it and install Set Screw. Do this one Set Screw at a time until all segments are “released”. 3. When all Set Screws are loose and segments have “released”, the Impeller is no longer “locked-up” and should be easily removed. 4. Clean and inspect all Release Collar parts.

02/07/2009

© Copyright Weir Slurry Group Inc. 2009

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Weir Minerals North America | BEARING ASSEMBLY INSTRUCTIONS FOR ‘M’ STYLE (SIZES M100 THRU M240)

WARMAN BASIC PART NUMBER AND PARTS LIST BASIC PART NUMBER 009 009D 023 024 046 046D 070 073 076 090 184 239 239A 239B 482 482D 506

02/07/2009

Bearing Bearing End Cover (Impeller End) End Cover (Drive End) Grease Retainer (Impeller End) Grease Retainer (Impeller End) Shaft Key Shaft Shaft Sleeve Bearing Nut Flinger Impeller Release Collar Release Collar Wedge Set Release Collar Cover Bearing Isolator Bearing Isolator Bearing Tongued Washer

© Copyright Weir Slurry Group Inc. 2009

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ISSUED: JUNE 1998

WARMAN INTERNATIONAL LTD.

WARMAN PUMPS ASSEMBLY AND MAINTENANCE INSTRUCTIONS SUPPLEMENT ‘M9’

GLAND SEALING

Warman International Ltd. is the owner of the Copyright subsisting in this Manual. The Manual may not be reproduced or copied in whole or in part in any form or by any means without the prior consent in writing of Warman International Ltd. Copyright © WARMAN INTERNATIONAL LTD.

ISSUED: JUNE 1998

MANUAL SUPPLEMENT ‘M9’

WARNINGS

WARMAN PUMPS - ASSEMBLY AND MAINTENANCE INSTRUCTION MANUALS AND SUPPLEMENTS IMPORTANT SAFETY INFORMATION • The WARMAN PUMP is both a PRESSURE VESSEL and a piece of ROTATING EQUIPMENT. All standard safety precautions for such equipment should be followed before and during installation, operation and maintenance.

• For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable speed drives, etc.) standard safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation and maintenance.

• DRIVER ROTATION MUST BE CHECKED before belts or couplings are connected. Personnel injury and damage could result from operating the pump in the wrong direction.

• DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS FOR PROLONGED PERIODS, OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORISE. Personnel injury and equipment damage could result from the pressure created.

• DO NOT APPLY HEAT TO IMPELLER BOSS OR NOSE in an effort to loosen the impeller thread prior to impeller removal. Personnel injury and equipment damage could result from the impeller shattering or exploding when the heat is applied.

• DO NOT FEED VERY HOT OR VERY COLD LIQUID into a pump which is at ambient temperature. Thermal shock may cause the pump casing to crack.

• FOR THE SAFETY OF OPERATING PERSONNEL, please note that the information supplied in this Manual only applies to the fitting of genuine Warman parts and Warman recommended bearings to Warman pumps.

• Tapped Holes (for Eye Bolts) and Lugs (for Shackles) on Warman Parts are for lifting Individual Parts Only.

• FULLY ISOLATE THE PUMP before any maintenance, inspection or troubleshooting involving work on sections which are potentially pressurised (eg casing, gland, connected pipe work) or involving work on the mechanical drive system (eg shaft, bearing assembly, coupling):• Power to the electric motor must be isolated and tagged out.

Copyright © WARMAN INTERNATIONAL LTD

MANUAL SUPPLEMENT ‘M9’

ISSUED: JUNE 1998

• It must be proven that the intake and discharge openings are totally isolated from all potentially pressurised connections and that they are and can only be exposed to atmospheric pressure.

Copyright © WARMAN INTERNATIONAL LTD

ISSUED: JUNE 1998

MANUAL SUPPLEMENT ‘M9’

ISSUED: June 1998 LAST ISSUE: July 1997 WARMAN PUMPS ASSEMBLY AND MAINTENANCE INSTRUCTIONS SUPPLEMENT ‘M9’ GLAND SEALING

CONTENT WARNINGS CONTENT INTRODUCTION ......................................................................................................... 1 GLAND ARRANGEMENTS ......................................................................................... 1 PACKING TYPES AND THEIR APPLICATION ........................................................... 1 Fitment of Packing in a Stuffing Box ............................................................................ 2 GLAND SEALING WATER FLOW AND PRESSURE REQUIREMENTS .................... 2 GLAND SEALING WATER CONTROLS ..................................................................... 3 TROUBLESHOOTING ................................................................................................. 4 REQUIREMENTS FOR THE GLAND WATER QUALITY ............................................ 6 Suspended and Dissolved Solids ................................................................................. 6

Copyright © WARMAN INTERNATIONAL LTD

MANUAL SUPPLEMENT ‘M9’

ISSUED: JUNE 1998

1

INTRODUCTION All end suction centrifugal Slurry Pumps normally have a shaft passing through the pump casing on the bearing side of the pump. All such pumps hence require a seal to seal the shaft. Packed gland seals have been traditionally used for many years and with proper care and attention can lead to a low cost and reliable sealing solution. The packing is housed in a Stuffing Box at the back of the pump casing. The shaft is normally protected with a sleeve. The sleeve can be made from wear resistant materials to prolong life and also protect the shaft. With water pumps, the pumped fluid can be used to cool and lubricate the packing running on the shaft sleeve. Slurry pumps have particles which would wear out a gland and lead to very short life. It is normal practice to inject clean sealing liquid (generally water) into the gland to flush solid particles away and also to cool and lubricate the gland.

GLAND ARRANGEMENTS Drawing A4-110-7-115795 shows the two main types of Warman Gland Arrangements for Stuffing Boxes. Types 1 and 2 are basically the same and utilise a Lantern Restrictor on the pump (slurry) side of the gland. Gland water is injected in the Lantern Restrictor. Type 1 uses a Metallic Lantern Restrictor and requires a high flowrate for the gland water. It is suitable for both Low Lift and Positive Head applications. Type 2 is differs from Type 1 as it utilises a Non-Metallic Lantern Restrictor. The gap between the Shaft Sleeve and bore of the Lantern Restrictor is smaller than Type 1. This reduces the amount of gland water flowrate required. Type 3 utilises a Neck Ring for injection of Gland Sealing Water. Instead of a Lantern Restrictor, a single round of Packing is used at the bottom of the Stuffing Box. This ring of Packing acts like a Lantern Restrictor to control the flow of gland water into the pump. Type 3 arrangements are used for high lift applications and generally have lower gland water flowrate requirements than Type 2. One disadvantage with Type 3 glands is the difficulty of maintenance.

PACKING TYPES AND THEIR APPLICATION Warman has three types of Packing depending on the pump application. Warman Material Codes are Q05, Q22 and Q23.

The

Q05 - This is a glass fibre filament and PTFE packing. It is a general purpose packing and is applied for lower pressure applications of 2 or 3 stages maximum. Q05 replaces the old asbestos Q01 post May 1989. Q05 is the standard Warman packing unless otherwise specified. Copyright © WARMAN INTERNATIONAL LTD

MANUAL SUPPLEMENT ‘M9’

ISSUED: JUNE 1998

Q22 - This is a synthetic aramid fibre with PTFE packing. It is used for high pressure glands for three and more stages of pumps. Q23 - This is a synthetic aramid fibre with PTFE packing. It is formulated to resist extrusion due to higher than normal gland water pressures and is the standard packing for the Warman Uniform Compression (type UC) gland. All three packing are used with Tungsten Carbide coated shaft sleeves - Warman material code J21. All three packing types have scarf joints. For multistage applications, packing Q22 has been proven to give long life. To reduce the extrusion of packing from the gland a packing retainer is normally used at the gland end of the stuffing box. FITMENT OF PACKING IN A STUFFING BOX The packing should be placed around the shaft sleeve and the scarf ends should be brought together. The joint should then be pushed into the annulus between the stuffing box and shaft sleeve. The rest of the packing should then be pushed into the annulus by starting near the joint and working around to the opposite side of the ring. Once the packing ring is started, push evenly all the way around the packing and gently push to the bottom keeping the packing as a ring.

GLAND SEALING WATER FLOW AND PRESSURE REQUIREMENTS Gland water must be supplied at the correct pressure and flow to achieve a long packing and sleeve life. Correct pressure is the most critical requirement to achieving satisfactory gland life. Flowrate is the next most important requirement. Flowrate is governed to some extent by the gland dimensions and also is adjustable within limits by means of the gland adjustment using the gland nuts. The gland water supply pressure must be controlled to acceptable limits. For normal gland operation, the gland water pressure should be set at +35 to +70 kPa above the pump discharge pressure. This ensures that water will enter the gland with sufficient pressure to flush solids away. If too low, the pump pressure can force slurry into the gland and even up the gland and even up the gland water pipe to the gland water pumps. This is too be avoid at all cost. Gland pressure that is too high will cause extrusion of the packing at the gland and pump ends of the stuffing box. Extrusion of packing causes both a degradation of the packing and less flowrate from the gland overtime. Both these things lead to packing failure. Up to +200 kPa above the pump discharge pressure should not cause too much degradation although the packing life is likely to be greatly reduced and high pressures are to be avoided.

Copyright © WARMAN INTERNATIONAL LTD

2

ISSUED: JUNE 1998

MANUAL SUPPLEMENT ‘M9’

The recommended, minimum total gland sealing water (GSW) flowrates for standard applications are: 0,1,080727$/*6:)/2:5$7(6 /PLQ Frame Size

TYPE 1 Metal Lantern Restrictor

TYPE 2 Non-Metallic Ryton (P50) Lantern Restrictor

TYPE 3 *Lantern Ring and Neck Ring

A

9

4

0.8

B, N, NP

15

6

1.0

C, P

21

7

1.5

D, Q

33

9

2

E, R

42

12

4

F, SHH

60

16

6

FAM, G, ST, S, T

100

26

9

GAM, H, TU

120

34

11

U

185

-

17

* Lantern ring is either metal (C23), Ryton (P50) or PTFE (P05) Notes: •

The metal lantern restrictor may be used when a larger GSW flowrate can be tolerated and where the type of pump duty requires high GSW flowrate e.g. mill discharge.

•

With the aging and deterioration of a pump gland the required GSW Flowrate can be up to three times (3x) higher than listed above. Any design of a GSW supply system should take this higher flowrate into account.

GLAND SEALING WATER CONTROLS There are a number of different gland water control devices that can be used viz. • • •

Visual Flow Indicator Throttle Valve Constant Flow Orifice Valve

Copyright © WARMAN INTERNATIONAL LTD

3

MANUAL SUPPLEMENT ‘M9’

• •

ISSUED: JUNE 1998

Combined Rotatmeter and Flowrate regulator or selected length of capillary throttling tube.

The most common type is a Constant Flow Orifice Valve. This type of valve is essentially a synthetic rubber O-ring housed in a socket. The O-ring shrinks in diameter as the supply pressure increases. This maintains a reasonably constant flowrate into a gland irrespective of the gland sealing water pressure. The Constant Flow Orifice is generally useful when there is considerable fluctuation in the gland water pressure. It can also assist when a group of pumps is fed by one gland supply line and one or more pumps are not operating or they have worn glands. In this instance, it can prevent starvation of gland water on the pumps which are operating.

TROUBLESHOOTING Most gland problems can be traced to two reasons: (a)

Inadequate or Excessive Gland Water Pressure Inadequate pressure results in contamination of the packing by the pumped slurry. Once solids are embedded in the packing, they cannot be flushed out and the packing must be replaced. Seal water pressure should be 35-70 kPa above the pump discharge pressure. Pressure in excess of this only results in more wear on the packing and shaft sleeve.

(b)

Inadequate Flow Like inadequate pressure, this results in contamination of the packing by the pumped slurry. Often this problem occurs with a seal water system which supplies several pumps, without flow control to each pump. In this case, the low pressure pump takes all the available seal water and starves the higher pressure pump. Flow to each gland should be controlled.

To achieve the above limits, it may be necessary to filter the water to at least reduce any solids content to the lowest practical. The gland sealing water supply must be reliable, as slurry pumps must not be operated without gland water supply, otherwise major gland problems will be experienced due to the high pressure forcing slurry into the gland region and causing wear and leakage.

Copyright © WARMAN INTERNATIONAL LTD

4

ISSUED: JUNE 1998

MANUAL SUPPLEMENT ‘M9’

352%/(0 Short Packing Life

Short Sleeve life

&$86( • Slurry wears packing

• Increase GSW pressure

• Slurry wears shaft sleeve

• Increase GSW flow

• Packing over heating and burning due to low GSW flow

• Loosen gland to increase flow

• Stop, cool down, repack and than restart with correct GSW pressure and flow

Slurry exists gland

Flow from gland too low in worst case steam exits from gland

62/87,21

• Pressure too high causing packing extrusion and flow restriction

• Stop, cool down, repack and than restart with correct GSW pressure and flow

• Gland too tight

• Loosen gland • Review type

• Packing too soft for high pressure

packing

• Use packing retainer ring • Reduce GSW pressure

GSW flows around outside of packing rings

• Packing rings wrong size or fit-up wrong

• Repack gland with correct packing • Review order of assembly

Too much flow from gland

• Shaft sleeve worn • Wrong size packing • Worn packing

Copyright © WARMAN INTERNATIONAL LTD

• Disassemble and refurbish gland with new parts

5

MANUAL SUPPLEMENT ‘M9’

ISSUED: JUNE 1998

CAUTION 1.

On no account should the gland be loosened to such an extent that it disengages from the stuffing box.

2.

Make adjustment to gland slowly and over a few hours time period. This particularly applies to new glands.

3.

Putting more rings into a stuffing box when problems occur will only be a short term fix. Extra packing will only exacerbate any problems. Repack and replace worn sleeve.

4.

Corrosion by saline GSW may be minimised by the use of appropriate alloys e.g. stainless steel, for critical components. However, the leakage of saline GSW from the gland must be trapped and conveyed to waste to avoid corrosion of the pump base and other components and equipment in the vicinity.

5.

Refer to further sealing instructions contained in Warman Supplement M1.

REQUIREMENTS FOR THE GLAND WATER QUALITY Water used for gland sealing should be clean and generally have the following properties. Failure to observe these conditions will result in excess time and effort being spent on gland maintenance. Many gland seal problems are blamed on pump design, when in fact, the seal water system can be the major cause. SUSPENDED AND DISSOLVED SOLIDS Water quality is an extremely important factor in gland seal operation. The following is a recommended water quality specification which is attainable with relatively inexpensive filtration treatment equipment:pH 6.5 - 8.0 Solids content: Dissolved: 1,000 ppm (mg/L) Suspended: 100 ppm (mg/L) 100% of +250 mesh (60 µm) particles removed. Maximum Individual Dissolved Ions: +

+

Hardness (Ca , Mg ) 200 ppm (mg/L) as CaCO3 Calcium Carbonate (CaCO3) 10 ppm (mg/L) Sulphate (S04-) 50 ppm (mg/L) Chloride (Cl-) 1,000 ppm (mg/L)

Copyright © WARMAN INTERNATIONAL LTD

6

MANUAL SUPPLEMENT ‘M9’

Copyright © WARMAN INTERNATIONAL LTD

ISSUED: JUNE 1998

7