Manual Bomba Warman 12x10 ST Ah

 

 Excellent Minerals Solutions

Weir ir Minera Minerals ls Latin A merica We Vulco Pe Perú rú S. S.A. A.

Instructions Operation & Maintenance  

INDEX

I.

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

General Arrangement Drawing Curve Component Diagram Bearing Assembly Part List

II.

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

III.

 Assembly and Maintenance Maintenance Instructions - SUPPLEMENT “P3” Series “A” Slurry Pumps – Type “AH & M”

IV.

 Assembly and Maintenance Maintenance Instructions – SUPPLEMENT “M8” High Seal Centrifugal Seal Type “HS”

V.

 Assembly and Maintenance Maintenance Instructions - SUPPLEMENT “BA1” Heavy Duty Bearing Assembly (Warman Basic Number 005) (Frame Sizes N,P,Q,R,S,T & U)

VI.

 Annex.

     

 

   H    A    0    1    /    2    1   p   m   u    l     P   a    t   n   o   z    i   r   o    H

   l   a   r    l    )   m  m   m   d   i   e   l   e   t   a   a   t   m  m    0   m  s    4   5    2   o   a   t    W    0   5   5   0   0   0   0   0   e   e    l    5   0    6    6   2   2   6   6   0   0   2    2   3    5   7   C   M    M   M    K   -   2   4   4   5   5   6   9   1   g   n    i    t    7   a   e    4    R   g   o   r   r    1    (    7   ø   a   n   e    N    4   0   s   o    l    i    1    h    l   e   e   e   t    t   p   c   r   1   e    0   M   e   c    X   n   n   p    l   s   m    X   u   p   a   a   y   a   1   A   a    F   F   T   T    G   m   i   a   u   D   S   m   V   V   T   P   G   F   r   F   F   F   S   S   G   G   T   e    P    I    F    S

    e   m  ,   a   r   r   e   F    t   a  .   w  e   c    i   n   t   a  o   n    h    t   t   r   u   e  o    h    t   h    t   o   i   w   a    i   s    d  r   e   l   e    l   m  e   r   p   o  m    F   i  .   t   e    )    d   l   e   e  e    i    f    i   d   c   r   e  o   p   /  .   s   d  r   e    t   e  n   a   s   n    i   e  e   c   w   r   c   g   e  n   a   n    h    t    i   r   o  m   u   r   t   s   f   o  c    l   e   s   e   a   r   f   u   n   p   u  p  n   a    2  m  m   e  u   h    d  p  c   a   r   e  a   e    G  g   -   n   a  m    h    9  c   r   o    9    f    9   t   o   e    1   :    l    b    6   t   a    0   h    l   g   i    9   i    9  r   a   e  v    O   a    h    t    S   y    I   s   l    i   r    d   r   e   a   v   a  r   s    d  e  s   n  s   e   c   a  e    t   r   e    S   S  n    t   L  e   s   r   e   A  a    T   R  s    l   E  e   a   v   n   N    i   o   I   t    i    t   M  a   n   a   r   n   e   r   R    I   t    l   e   E    I    t   n   W  a   e    (  .   m   s    R   a    d   r    l   f    E   i    T  o    l    l   s    A   f   a    W  o   t   o   s   N    t    R   c  .    A  e   t    E   f   n    f    L  e  e    C  r   m   e  e    R    h  g    t   n    O   a    F  o   r   r   r   o    E   /   a    d  e    C   v    N  n    i   r    A  a   d   y    t    M    i    d    R  s   o  n    O  c   a   s   y    F   i    R  v   t   u  ,   d    E  y    P   t    i   h   c    E  s    T  n   e  a   e    A   d  r   r   o    M    I   f   o   f    X    d   e    R    O   e    d   a   k    P  m  c   e    P    h   e  c    A   b   e    S   t   b   s    W  u   t    O  m  s   u    H  s   m    S  n    0   y   o   i    t    i    E   t    9    l    V  c   i    b   e    R  r   a    t    i    U  r   o  u    C  c   s

   I    I   e   s   a    F   o    %   d   n    i    8   o   L    7   p    l    l    i   o   r    M  r   e    C   a   r    0   e   o    7   n   t    2   i   c    1   M  e    1   y   a   o    I   i   r    N   C   P

   %    0    8

   )   p    i   n   m   m   u    P    /   r    d   x   0   0   e   a   5   2    l    0   a    M   6   1   e   z   e    i    S   m    S   r    d   o   e   n   g   a    N   r   a    l    (   s   e    G

  m   m    6    8

  s   m   l   a   a   r   y   t    P   e   l   o   e   n   n   P   M   i    i    L    M

    a    j   a    C    @    h   s   a      l    F   s    D    /   s   a    C   a   d    4    d   n    0    l   e   a    0      C  r   a    1    Z    5   a   g   e   2   1   r   d    4     a    º   0   c    N   0   s   a   r   e   o   o   4      D   d   n   5    i    i    l   u    0   a   o    b   b    i   :   r   M     G    t   m    l   s   o   i   e   A 8m    B   d    d   T

   5    2   8    0   T   8    0   S   b    8   E   e    1    S   T   F   s   A   e   W    t  .   o   n    N   i   e   m  c   n   n   /   o   r   n   o   i   e   d    i   s  .   r   s    i   e   e   e   i   u    f   v   v   X   v    A   e   s   e   e   r   R   s   u    R   M   R   I

   C

  :    S    E    N   s    O   a    I   1   r    7    8   c  .   5   i    C   1    A   =  m    R  =   a   o   s   0    E  p   e   8    D    l    P    I   u   l  .   1    S  p   =  .   ò   0    N   E    O  .   S   5    C   G   %    D

  s    /   m    0   5    5   2    3   =  .   =   i    f   y   r   r   e   r   P   u  .    l   s   c   o    P   l    H  e    B   V

   )  .   m  .    Y  n  .    C  s    N  .    E    I   m    C    I   0    F   0    F   2    E   2    t    M  a   r    U    I   e   w    M  o    E  p    R    P   e   v    R   P   R   i   c    O   H   O   t   e    T   0   T   f    f    O   0   O  e    (    5   M    M

   )    C    T    E    P    V    (   a    R    U    i    l    C   a   r    d    t   e    E   s  v    C   u  r    N    A    A  e   s    M   s  e    R    l    O   a   r   R    F   s    R   e   t   n   h    E    i    P   g    P    M    i   r    i   R    M   e   l    l    U    P    A    L    W    1    A    C    1    I    0    P    Y    2    T    /    7    ©

   1    /    1    0    A    0    1    2    1    A    P    W

   0    0    0    2

    N     P     S   r    H

   %    8    7

6m

  r    h    /    ³   m   m   r   m   m  m  p    0  .   r   4   5   5   4    3   r  .    2  .  .   o   3   5   5   6   %    4   W    C   1  .   =   k   0    0    1   3   3  =   4  .    0   1   o  =  =  =    8    7   r    4    d    )   m    )    1    H   =    i   e   =   x   w   L    S   o   S   a   l    (   e    (   W   p   f    f   P   =  m    F   H   H   S   E   N   P   S    M

   %    5    7    %    0    7

  r    h    /    ³   m   m   p   r   m    0   m   m  .    9    2    4   0    0  .  .   9   % .   W    3   2   2    4    1   3   3   5   7  .   =   k   0    0    1  .   o  =  =  =  =   8    1    7   r   6    2    d    )   m    )    1    i    H   e   =   =   S 4m   x   w   L   a   l   o   S    (   e    (   W   p   f    f   P  =  m    F   H   H   S   E   N   P   S    M

   0    0    0    1

3m

   %    0    6

     Y      C      N      E    I      C    I   r      F      F    h    /     E

  m    ³   m  m  m  p   r   m   r   r   8    3    5  .   0  .    0   o   6    8    % .  .    2   5    3   W    C   4   2  .   =   k   0    l   9   3   3  =   9    0  .   a   =  =    6    7   1    7   r   n   =    0    d    i    )   )   e    H   1   =   S   =   m  w   L   o   S   o   l    (   e    (   W   p   f    f   P   =  m    N   F   H   H   S   E   N   P   S

  r    h    /   m    ³   m  m  m  p   r   m    0    7    4  .   0    0  .    5  .  .    6   9   9   5   %    3   W    0    2   2    7  .    l    4    9  .   =   k   0   a   =  =  =   7   n   =   )   )   d   7  r   6   1    i    9    H   e   =   m  w   L    S   =   o   S   o   l    (   e    (   W   p   f    f   P   =  m    N   F   H   H   S   E   N   P   S

2m

   %    0    4

  m   p   r    0    0    9

   0    8

  m   p   r    0    0    8

   0    7

   0    6

  m   p   r    0    0    7

   0    5

  m   p   r    0    0    6

   0    4

  )   m   (   H ,  d   a   e    H

   0    3

  m   p   r    0    0    5

  m   p   r    0    0    4

   0    2

  m   p   r    0    0    3

   0    1

   )   r    h    /    ³   m    (    Q  ,   e    t   a    R   w   o    l    F

 

Weir Minerals Latin America

 Excellent

Vulco Perú S.A.

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Listado de Partes  

WARMAN 12/10 ST-AH

D-VP-1X-871 Rev. A

TIPO SELLO CENTRIFUGO ITEM

DESCRIPCION

REVESTIMIENTOS EN CAUCHO CANT

CODIGO VULCO

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

BEARING ASSSEMBLY (REF. DW G. A1-105500) NAMEPLATE NAMEPLATE RIVET TLP/D424BS BASE CLAMP BOLT - 1 NUT CLAMP W ASHER EXTRA LARGE W ASHER FRAME PLATE LINER STUD FRAME PLATE LINER FRAME PLATE IMPELLER (AS SELECTED) COVER PLATE W ARNING PLATE - IMPELLER REMOVAL COVER PLATE LINER VOLUTE LINER SEAL

1 1 10 1 4 4 8 8 1 1 1 1 1 1 2

SH005M B6C22 ST003MD21 F012ME62 F011E63 M12-22-Z M12Z3-75ZL G10036TL1HS1R55 G10032HSPRD21 G10147A05 G10013D21 SB83C22 G10018TL1MR55 G10124S01

1 16 7 18 19 20 21 22 23 24 25 26 27

T H STUD TH HR RO OA AT TB BU US SH INTAKE JOINT RING COVER PLATE LINER STUD COVER PLATE BOLT - 2 NUTS FRAME PLATE STUD - 2 NUTS SHAFT SLEEVE O´-RING IMPELLER RELEASE COLLAR ADJUSTING SCREW - 3 NUTS - 2 W ASHERS W ARNING PLATE - BURSTING W ARNING PLATE - LIFTING GUARD CAUTION LABEL

1 4 1 6 8 3 3 1 1 1 1 1

G M12000Z833-M 75RZ5L5 G10060S01 M12Z3-45ZL G10015ME63 G039ME63 CSC210S10 S239MC21 S001ME62 SB73C22 SB80C22 LBL102

CENT. SEAL METAL EXPELLER RING ONLY

48 49

SEAL GUARD SET SCREW (SEAL GUARD)

1 2

ST12485T3C23 M16H2-30SW

51 0 5 52 53 54 55 56 57 58 59 60 61 62

SH SLCEUEPVE G RA EF ATSE ADAPTOR G GR REASE CUP CLAMP PLATE SET SCREW (CLAMP PLATE) EXPELLER RING IMPELLER O'RING EXPELLER RING O'RING EXPELLER PACKING LANTERN RING GLAND BOLT - 1 NUT - 1 W ASHER GLAND (2 PIECE)

1 1 1 1 1 1 1 1 1 2 1 4 1

S1 H3087-51C G E2612 W P4L84-L F8022HS1E62 M12H2-20S G10029HS1A05 G109S10 69T702N SH10028HS1A05 G111Q05 G063HS1P05 G045MC23 G044C23

 

Weir Minerals Latin America

 Excellent

Vulco Perú S.A.

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 Minerals

Listado de Partes   WARMAN 12/10 ST-AH BEARING ASSEMBLY SH005 ITEM

DESCRIPCION

CANT

CODIGO VULCO

1

SHAFT KEY

1

S070M

2

SHAFT

1

SH073M

3

SETSCREW LOCK

2

M12A2-30H

4

GREASE NIPLE

2

UP2L73-Z

5

LABYRINTH LA

1

S062-10

6

BEARING L.A.

2

S009D-C3

7

NAMEPLATE

1

-

8

NAMEPLATE RIVET NA

2

-

9

BEARING HOUSING

1

S004M

10

PLUG 1/4" NPT

2

UP4P1-E

11

END COVER

2

S024-10

12

BEARING SEAL

2

FF089-10

13

LABYRINTH L.A.

1

S062DM-10

14

END COVER SET SCREW

16

S027M

15

BEARING

1

S009

16

SHIM SET

2

S025

17

PISTON RING

4

S108

   

 A s s emb  As em b l y & Main Mai n t enan en anc ce Instructions Sup uppl ple ement ‘M1 ‘M1’’ General Inst General Instruct ruct ion  Ap p l ic abl ab l e to all t yp es o f War Warm m an Pum Pump ps

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

Office of origin :

Pump Technology Centre, Artarmon

Reference :

Pump Manuals

Date :

22 January 2007

Last Issued:

July 2005

   

Weir Minerals

| M01 General Instructions for All Pumps Jan 07.doc 

Warnings Personnel injury and / or equipment damage could result from not observing the following IMPORTANT SAFETY INFORMATION.    A 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, mechanical seals, etc) all related safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment   and maintenance.    All guards  for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards should not be removed or opened while the pump is running. Personal injury may result from contact with rotating parts, seal leakage or spray.   Driver rotation must b e checked checked  before belts or couplings are connected.   Pumps must not be operated 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 high temperature and pressure created.   Pumps must be used only within their allowable limits  of pressure, temperature and speed. These limits are dependent on the pump type, configuration and materials used.   Do not apply heat heat to t he 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.   •

•

•

•

•

•

•

•

•

LIFTING of components

  Tapped holes (for eye bolts) and lugs (for lifting shackles) on Warman pumps are for

•

only . lifting Individual parts only.

  Lifting devices devices of adequate adequate capacity capacity must be used used wherever wherever they are are required to be

•

  used. Safe workshop practices should be applied during all assembly and maintenance work.   Personnel must never work under suspended loads.   The pump must be fully isolated   before any maintenance work, 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.   •

•

•

•

23/01/2007

 

© Copyright Weir Minerals Australia Ltd

Page 2 of 34

 

Weir Minerals

| M01 General Instructions for All Pumps Jan 07.doc 

Castings   made from materials listed are brittle and have low thermal shock resistance.  Attempts to repair or rebuild by welding may cause catastrophic catastrophic failure. Repairs of such castings using these methods must not be attempted - A03, A04, A05, A06, A07, A08, A09,  A12, A14, A49, A51, A52, A53, A53, A61, A210, A211, A217, A217, A218, A509.

  Impellers  must be tight t ight on the shaft before any start-up, ie all components on the shaft between the impeller and the pump end bearing must butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking etc.   Burning  of elastomer pump components will cause emission of toxic fumes and result in air •

•

pollution which could lead to personnel injury.

  Leakage from the pump shaft seals and/or leakage from worn pump components or seals may cause water and/or soil contamination. contamination.   Liquid waste disposal  from servicing of pumps or stagnant water from pumps stored for long periods, may cause water and/or soil contamination.   Do not apply anti-seize compounds   to the impeller or shaft threads or to elastomer seals during assembly. Anti-seize can greatly reduce the impeller thread friction and may cause the impeller to loosen during pump shut-down and run-back resulting in pump damage, or the elastomer seals to leak at reduced pressure.   This manual applies only to genuine Warman parts  and Warman recommended parts.   Mixing of new and worn pump parts  may increase the incidence of premature pump wear and •

•

•

•

•

leakage.

  Large foreign objects or tramp  entering a pump will increase the incidence of higher wear and / or damage to the pump. Routine inspection and maintenance of mill trommel screens will assist to reduce the danger of grinding balls entering a mill discharge pump.   Large variations in slurry properties may lead to accelerated rates of wear and corrosion of pump components eg   Wear increases exponentially exponentia lly with velocity and slurry particle size.   Corrosion rate doubles for every 10 degree Celsius increase in slurry temperature. temperature .   Corrosion rate increases exponentially exponentiall y as slurry pH decreases. •

•

• • •

23/01/2007

 

© Copyright Weir Minerals Australia Ltd

Page 3 of 34

 

Weir Minerals

| M01 General Instructions for All Pumps Jan 07.doc 

ISSUED: JANUARY 2007 LA ST ISSUE: JULY 2005

WARMAN PUMPS

 ASSEMBLY AND MAINTENANCE MAINTENANCE INSTRUCTIONS INSTRUCTIONS SUPPLEMENT SUPPLEME NT ‘M1’ ‘ M1’

General Instruction  Applicable to all all types of Warman Pumps

 

CONTENTS WARNINGS

2 

CONTENTS

4 

1 

INTRODUCTION

6 

GENERAL

6 

PUMP IDENTIFICATION

6 

FOUNDATIONS

8 

SHAFT ALIGNMENT AL IGNMENT

8 

 AL IGNMENT, TE TENSIONING NSIONING AND ADJUSTMENT OF V VEE-BELT EE-BELT DRIVES

8 

2 

3 

 AL IGNMENT O OF F DIRECT CO COUPLED UPLED PUMPS

11 11  

PIPEWORK

13 

Flanges

13 

Intake Conditions

13 

OPERATION

14 

GENERAL

14   14

SHAFT SEAL

14  14 

SHAFT UNLOCKING

15 15  

MOTOR ROTATION CHECK

15 15  

PRIMING

15  15 

NORMAL PUMP START UP

16 16  

 ABNORMAL  AB NORMAL START UP

17 17  

Blocked Intake Pipe

17 

 Air Entering Gland

17 

OPERATING FAULTS

17 17  

Low Pit Level

17 

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Blocked Intake Pipe

18 

Blocked Impeller

18 

Blocked Discharge Pipe

18 

SHUTTING DOWN PROCEDURE

18  18 

MAINTENANCE

19 

RUNNING MAINTENANCE

19 19  

General

19 

Shaft Seal Care

19 

Repacking Gland

20 

Impeller Adjustment

20 

Tightening Down

21 

5 

6

Labyrinth Grease Purging

21 

Bearing Lubrication

21 

OVERHAUL MAINTENANCE

22  22 

General

22 

Pump Dismantling

22 

Inspection & Removal of Bearings

23 

Replacement of Wearing Parts

24 

Reassembling Pump Overhaul

25 

COMMISSIONING COMMISSIONIN G OF PUMPS

26 

STORAGE OF PUMPS & STAND BY PUMPS SPARE PARTS

26  26  26 26  

APPENDIX A

31 

SEAL TYPES, PROBLEMS AND SOLUTIONS

31 31  

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INTRODUCTION General

This Supplement sets out general instructions for the installation, operation and maintenance applicable applicable to all TYPES of Warman Warman Pumps. These instruc instructions tions 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 Identific Identific ation

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: DIGITS

LETTERS

LETTERS

(a)

(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 itsize is taken by asa the discharge It isetc. given in millimetres, is expressed number such asdiameter. 100, 150, 200

2.

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

(a1)

DIGITS

/

INTAKE DIAMETER

(a2) DISCHARGE DIAMETER

(i)

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

It is expressed as a

(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.

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(b)

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 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 the range denotes denotes the smallest fra frame me 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, and H: Slurry pum pumps ps with replaceable replaceable line liners rs  AHP, AHPP, HP, and HPP: Slurry pumps with high pressure casings and

replaceable replaceabl e liners.

D, G, and GH: Dredge and gravel pumps S, SH: Solution pumps TC: Cyklo pumps PC, PCH: Process chemical pumps SP, SPR, and GPS: Sump pumps

 AF, A HF, LF, an d MF : Froth pumps GSL: Flue Gas Desulphurisation pumps 

High head pumps are generally denoted by an '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 (high pressure pressure AH pump)

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FOUNDATIONS Efficient pumpSteel service can be should obtained by concrete installing foundations the pump on adequate foundations. foundations be only robust, heavy. Both should be designed to take all loads from the pump and motor and to absorb any vibrations. All holding down bolts bolts should be fully 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 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 Sha ft Ali gnment

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, drives, non-parallel shafts shafts cause excessive excessive be beltlt wear. Rigid couplings 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 coupling fitted between the pump pump and diesel prim prime e mover is

recommended.  Al ig nment nm ent,, Tens io ning ni ng and Ad ju st men mentt o f Vee-B Vee-Belt elt Dri Drives ves

For optimum performance of Vee-Belts, only new matched sets of belts should be used (belts should lie within a range of of 2 to 4 set numbers according to the belt leng length). th). 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.  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.

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Use a good straight straight edge across across both motor motor and pump pulley 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. WARNING  AFTER PUMP IMPEL LER ADJUSTMENTS A DJUSTMENTS RECHECK THE PULL EY AL IGNMENT  AND A DJUST A S NECESSARY B EFORE RESTARTING THE 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 tensioning follows: (a)

Measure the length of span

(b)

Apply a force at right angles angles to the belt at the centre o off the span ssufficient ufficient to deflect one belt by 16 mm per metre of span

(c)

Compare the force force required with the value 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 satisfactory below or above the vvalue alue stated, the belt should be tightened tightene d 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 drop in tension durin during g the normal running running in period. New belts should be run under load for two hours, stopped, and the tension re-checked, resetting the adjustment adjustment to achieve the correct tensi tension on 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, cartridge, as well as the loss of transmis transmission sion efficiency. 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 shortens their lilife. fe. Furthermore, bearings

will tend to overheat due to excessive radial forces on the rolling elements and this will lead to premature bearing failure.  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 maintenan maintenance ce intervals.

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span

16mm deflection per metre of span

Force

Belt Section

Small Pulley Diameter (mm)

Force required to deflect belt 16mm per metre of span; Newt Ne wt on (N)

SPZ

56 to 95

13 to 20 

100 to 140

20 to 25 

80 to 132

25 to 35 

140 to 200

35 to 45 

112 to 224

45 to 65 

236 to 315

65 to 85 

224 to 355

85 to 115 

375 to 560

115 to 150 

SPA SPB SPC

 A

80 to 140

10 to 15 

B

125 to 200

20 to 30 

C

200 to 400

40 to 60 

Figure 1: 1: Align ment, Tensioni Tensioni ng and adjust ment of VeeVee-Belt Belt

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 Al ig nment nm ent of Dir ect Cou pl ed Pu mp s

In a direct coupled drive, misalignment causes unnecessary vibration and wear on the bearings. Rigid couplings couplings (ie couplings couplings that bolt directly together without without any flexible member in between) should be avoided and must not be used without consultation with Weir Minerals Division. The following procedures procedures outline a sugg suggested ested practice for checking checking shaft alignm alignment. ent. 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 shouldDial be loosely coupled, each halfbemust be free to movetightly relativefittin to gthepins other or the resulting Indicator readings readings can incorrect. Where fitting or springs prevent loose coupling, the pins or springs should be removed, a line scribed across both half half couplings and the readings readings taken only when the two are aligned. 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.  An gu lar sh aft ali gn men t : 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 figure below below and clamp two Dial Dial Indicato Indicators rs (DI) at diametric diametrically ally 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 ver vertically, tically, and set the gauges to read zero.

(d)

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

(e)

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

(f)

Repeat operation (d) and and adjust adjust the unit position position until the correct tolerance is achieved and no further adjustment is necessary.

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Radial shaft alignment:

To ensure that radial shaft alignment is correct proceed as

follows: (a)

Clamp a DI to one half coupling coupling or to the shaft, 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 tolerances given. Refer to p paragraph aragraphss 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 other allowances must be made. The units should then be realigned when each have attained their correct operating temperature.

Follow the manufacturer’s manufacturer’s recommendation. recommendation. If no rrecommenda ecommendation tion is available the limits of accuracy within which adjustments must be made cannot be specifically specifical ly defined because of differences in the size of and speed speed of units. However, the following variations which can be tolerated when checking alignment and are suggested as a general guidance. Tolerances:

1.

Angular Alignment:

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

Figure 2: Alignm ent of Direct Coupled Coupled P Pumps umps

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2.

Radial Radial Alignment:

Not to exceed 0.1 mm on Dial Indicator I ndicator (ie 0.05 mm eccentricity) Figure 2: Alignment of of Direct Coupled Coupled Pumps

Pipework

Pipelines and valves should be properly aligned with pump flanges and they should be supported independently independently of the pump. pump. All pipe design should 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 Weir Minerals Division.  APPROPRIATE WARMAN JOINT RINGS (when required) MUST BE USED AT THE PUMP FLANGES. FLANGES. THE JOINT JOINT RINGS FORM AN EFFECTIVE SEAL SEAL BETWEEN PIPEWORK AND PUMP CASING. In some pum pumps, ps, the metal liner liner projec projects ts a short distance past the flange. flange. Care should be taken taken in such instances 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 be airtight to ensure priming priming of the pump. pump. Recommendations and procedures for inter-stage piping for multi-stage installations are available from Weir Minerals Division. Flanges

Matching flanges on the pump intake and discharge must be flush as shown on attached drawing A4-111-1-121595. A4-111-1-121595. Keeping flanges flush is important important in providing proper backup 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 Conditi Conditi ons

Suitable isolation should be fitted in the intake pipe as near 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 more pumps operating operating on suction lift is not recommended 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 diameter of the intake branch of the pum pump. p. 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.

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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 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.

3

OPERATION General

The principle requirements for operation of Warman pumps are as follows:   Priming arrangements to raise water in the intake pipe pipe and fill the pump.   Gland sealing water (on gland sealed pumps) provided at adequate pressure and flow.   Impellers adjusted to maintain maintain minimum clearance with front liner.   Wearing parts replaced replaced when p performance erformance falls falls below required operating operating pressure.   Volute liner seal and stuffing stuffing box seal maintained to pre prevent vent lleakage. eakage.   Grease purged labyrinths (where used) used) lubricated lubricated regularly regularly to prolong bearing bearing life by excluding dust and dirt from the bearing assembly. •

•

•

•

•

•

WARNING ENSURE THAT THAT A LL GUARDS ARE IN PL ACE A AND ND SECURE PRIOR PRIOR TO OPERATING OPERATING THE PUMP 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 approximat ely 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 and adjust it so that a sma smallll flow is obtained along along the shaft. Note that pumps supplied directly from Weir Minerals factories usually have tight glands to minimise shaft vibration during transport. WARNING  ANY A DJUSTMENT OF THE GLA ND SHOULD ONLY ONL Y BE CA RRIED OUT WHILE THE PUMP IS STOPPED TO AVOID POTENTIAL INJURY FROM ROTATING PARTS

For centrifugally sealed pumps, screw the grease cup down a few turns to charge the static seal chamber with grease. Supplement M8 contains further information on Centrifugally sealed pumps and supplement M9 contains further information on Gland sealed pumps. Technical Bulletin number 27 and Appendix A contains general information and application guidelines on the three main types of shaft seal – Gland, Centrifugal and Mechanical Seals.  Appendix A in this manual contains some specific information pertaining to mechanical seals. 23/01/2007

 

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WARNING REMOVE THE MECHANICAL SEAL REMOVE SEA L SETTI SETTING NG TABS TAB S AND TORQUE TORQUE THE LOCKING COLLAR FASTENERS TO THE SPECIFIED VALUES PRIOR TO STARTING THE PUMP, OTHERWISE SERIOUS SEAL AND PUMP DAMAGE COULD RESULT Shaft Unlocking

For transport of Warman pumps the bearings can be locked to prevent vibration and consequent conseque nt damage. Note that it is not absolutely critical critical to lock the bearings as small movements help help to prevent false brinelling. Clamping is done done by attachin attaching g the shaft clamp to the shaft. shaft. A set screw screw in the handle of the clamp is then screw screwed ed up hard against the pump base to lock lock the bearings. Alternatively, the pump is supplied 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 vee-belt tension must be ch checked ecked and adjusted adjusted if necessary. necessary. The shaft should then be rotated by hand (clockwise) by means of the clamp to ensure that the impeller turns freely within within the pump. At any sign of scraping scraping noises from the pump, pump, the impeller must be adjusted (see Assembly and Maintenance Instructions for the particular TYPE of Warman pump). pump). The shaft clamp clamp must then be removed. removed. 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 arrow on the pump pump casing. Refit vee-belts or reconnec reconnectt shaft coupling 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) installation) must be prov provided ided in prepara preparation tion to starting up. Gland sealing sealing water should then be be turned on to the pump(s). pump(s). To ensure trouble trouble free operation o off 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, namely, start up, running, shut down and run b back. ack. 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. 

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Normal Pump Start Up

Check once once more that all bolts are are tight and that the impeller impeller turns freely. 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. stream. On shutting down down it is also desirable desirable that pumps should should be allowed to pump water only for a short period before shut down. Open intake valve (if any) any) and check that water is availab available le at the inlet. Check drai drain n valve (if any) is closed.

If a discharge valve is installed installed it is common common practice to close it for sstart tart 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 pump is primed, isolate prime fac facilities ilities (i (iff 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. leakage. If leakage is excessive excessive tighten gland nuts until flow is reduced to the required level. level. If leakage is insufficient insufficient and gland shows shows signs of heating, then try loosening gland nuts. nuts. If this is ineffective and the gland continues continues to heat up, the pump should be stopped stopped and the gland allowed allowed to cool. Gland nuts should should not be loosened to such an extent that the gland follower is allowed to disengage the stuffing box. WARNING  ANY A DJUSTMENT OF THE GLA ND SHOULD ONLY ONL Y BE CA RRIED OUT WHILE THE PUMP IS STOPPED TO AVOID POTENTIAL INJURY FROM ROTATING PARTS 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.  gland.  

 At low pressures pressures (single stage operation) operation) very little leakage leakage is required and and it is possible to operate with only a small small amount of water issuing issuing from the g gland. land. 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. persists, the packin packing g should be removed removed and the glan gland d repacked. If heating of gland persists, Warman pumps are normally packed with non-asbestos packing, Warman material code Q05, for general duties and pressures pressures up to 2000 kPa. Above 2000 kPa it is us usually ually necessary to use an anti-extrusion ring between the gland follower and the last ring of packing. High pressure packing recommendat recommendations ions are available from Weir Minerals Division.

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For multi-stage installations it is usually necessary to time the starting of the second and subsequent stage pumps to prevent motor overload. Recommendations Recommendati ons and procedures for start up are available from Weir Minerals Division.  Ab no rm al St art 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 gauge on the intake side of the pump may be us used ed to check the level of water in the pump.  Ai r En ter in g Gland Gl and

If one of the following conditions applies, air may be induced into the pump through the

gland. This may prevent prevent the pump "picking "picking up" its prime or cause it to loss its prime during operation.        

• • • •

Sealing water pressure too low Packing is excessively worn Shaft sleeve is excessively worn Gland sealing water connection into stuffing box is bl blocked. ocked.

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 cause of any problems. Some of the major faults that can oc occur cur 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 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 DISCHARGE VAL VE Low Pit Level Level

Pumps (or first stage pumps in a multi-stage installation) may lose their prime if air is induced through through the gland. Pumps may also lose their 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

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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 thereby cause a partial obs obstruction. truction. Such an obstruc obstruction tion 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. Block ed Impeller Impeller

Impellers are capable capable of passing a certain certain size particle particle.. If a particle larger in size enters enters the intake pipe it may become lodged in the eye of the impeller thereby restricting the output of the pump. Such an obstruc obstruction tion will usually result in a drop of amps and a drop in both discharge discharge pressure and and intake vacuum vacuum readings. Pump vibrations will will also occur due to the out of balance effects. WARNING BEFORE APPLYING MANUAL TORQUE TO THE PUMP SHAFT ENSURE THAT THE INTAKE A ND DISCHARGE LINES ARE ISOLATED AND THAT THA T THE MOTOR MOTOR IS

DISCONNECTED Block ed 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. 2. 3. 4. 5.

Close the discharge discharge valve (if fitted) to reduce load on driving unit Shut down the pump Shut intake valve (if any) If possible possible flush pump with clean water and let it discharge through the drain valve. Gland sealing water (if any) any) must be left on during all ssubsequent ubsequent operations operations,, namely: Start up, running, shut down and run back. Gland water may only then be turned off.

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Weir Minerals

4

MAINTENANCE Running Maintenance General

Warman pumps are of robust construction and when correctly assembled and installed, they will give long trouble-free t rouble-free service service with a minimum amount of maintenance. The only maintenance required for pumps 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 pressure rises leakage leakage will necessarily be excessive. excessive. If glands are adjusted to provide optimum leakage at the higher seal water pressures, insufficient lubrication will be obtained when this pressur pressure e 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 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 water leakage along the sshaft haft by regularly adjusting 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 them to run run in a dry condition. Use o only nly reco recommended mmended clean lubricant. Repacking 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 packing should then then be placed in posi position tion 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 should then be slacke slacked d off and left finger tight until pump is started. After start-up glands maybe maybe adjusted until leakage leakage is at the required flow rate. These glands are designed for water lubrication and some leakage is necessary during operation to lubricate lubricate and cool the packing packing and shaft sleeve. sleeve. Gland leakage a att all times must be clean and free from from solids. If there is any sign of slurry slurry leaking from a gland then 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 position in the stuffing box. The stuffing box, assembled assembled gland and and shaft sleeve may then be fitted to the pump as one unit. Impellerr Adjust ment Impelle

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

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carried out in a few minutes without without any dismantling. The correct setting setting of the impeller is when the clearance between the impeller and the intake side liner is a minimum. WARNING PRIOR TO TO IMPELL IMPELL ER ADJUSTMENT, THE THE MECHANICAL SEAL LOCK TABS TA BS MUST BE INSTALL ED AND THE LOCKING COLL COLL AR RELEASED IN ORDER TO TO ALL OW THE FREE MOVEMENT OF THE BEARING ASSEMBLY.  AFTER PUMP IMPELLER IMPEL LER A DJUSTMENT, RECHECK THE PULL EY AL IGNMENT AND  ADJ UST AS NECESSA RY AND RE-L OCK THE MECHANICAL MECHA NICAL SEAL LOCKING LOCK ING COLLAR COLLA R AND REMOVE THE LOCK TABS. 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 recommended therefore therefore that that a routine maintenance program be established whereby a check is made at regular intervals to ensure that all nuts are tight. To avoid any possible possible movement between between the Bearing Assem Assembly bly and the Base, the Bearing Housing Housing Clamp Bolt must be maintained fully tighten tightened. ed. (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 where bolts consistently consistently loosen then 'Ny 'Nylock' lock' nuts or other suitable locking devices should be fitted. Labyrinth Grease 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 contaminant entering the bearing assembly will result in longer bearing life and ultimately cost savings. Therefore careful attention attention paid to labyrinth p purging urging is an essential maintenance requirement. Full details are given in the relevant Warman Bearing Assembly Instruction Supplement. Supplement. Bearing Lubrication

 A correctly assembled assembled and pre-greased pre-greased bearing bearing assembly will 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 supplement depending on the type of bearing assembly in use.

BA

maintenance

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 determine the effectiveness of the re-lubrication 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 t he 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 amounts at long intervals. intervals. Bearings must must never be ov over er 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 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, 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 reconditio ned in a workshop preferably in a specific area set aside for the work. work. A clean environment environment is essential. Pump Dismantling

Isolate the pump from the system and wash wash down as much as poss possible. ible. 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. Note that the pump must be dismantled before the bearing assembly can be removed for reconditioning. 23/01/2007

 

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 All Warman pumps utilise a thread to fasten the impeller to the pump shaft. The larger pumps incorporate incorporate an impeller release collar to facilitate impeller remov removal. al. Full details can be found in Warman Supplement 'M2'. Inspection & Removal of Bearings

Since greasing requirements varybe with operating conditions and environment the following general recommendations should used as a guide. When new bearings are fitted or re-assembled after overhaul they should be correctly packed with grease. grease. It is then recommended that a systematic systematic program of of investigation be instituted in order to ascertain the following:   whether the grease addition is required between overhauls   how frequently frequentl y 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 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. The criteria for examination of a bearing is contained in the question "Will the bearing operate until the next next overhaul?" Where there is any any doubt regarding th the e 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.

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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 (stained) 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 Re moving Bearings 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 parts must not be mixed mixed with new new parts. A complete new bear bearing ing 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 abrasive properties properties of the material handled. handled. Therefore, the lilife fe 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 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. Replacement of the impeller only, will result in the pump regaining almost new pump performance. Whether liners require replacement should be assessed by estimati estimating ng whether the proportionate thickness remaining will provide reasonable further life before replacementt is required. replacemen

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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, intervals, parts be inspected and their wear rate estimated so that the remaining life of the parts may be established. established. For installation of new wearing parts refer to relevant Warman Pump Supplement. Reassembling Re assembling 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 t heir effectiveness.

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5

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 clearance is preset preset for give optimum optimum efficiency efficiency but but this should be ch checked ecked and adjusted. Refer to the section on impeller adjustment adjustment in this supplement. 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. Check and adjust seal leakage.   All guards are fitted in place and secure.

• •

Storage of Pumps Pumps & Sta Stand nd By Pumps

Store only clean pumps. pumps. Pumps taken out of service service should be flushed with wate waterr and dried before storage. Indoor storage is is recommended recommended especially for elastomer pumps. pumps. Too much heat can can artificially age elastomer elastomer and render render it unserviceable. unserviceable. For outside stored p pumps umps 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. pressure on the packing.

Remove transport clamps and loosen gland to release

Turn the shaft of the pump pump a quarter of a turn by by hand once per per week. In this way all the bearing rollers in turn are made to carry static loads and external external vibrations. Ensure that the rust preventing coat of the shaft drive end is maintained. Specific recommendations recommendations can be obtained from Weir Minerals Division. Spare Parts Parts

Spare parts for Warman pumps consist in the main of liners, impellers, bearings, shaft sleeves, seals seals and shaft seal parts. parts. Depending on the the expected life of ea each ch 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. size. This enables a quick change of the bearing assembly in any one of the pumps. Often this operation is carried carried out when wearing parts are bein being g 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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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

Table Table 1: Bea Bearing ring Housing Clamp Bolt Torque

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Fault Finding Chart

  s   w   o    l    f   r   e   v    O   r   e   p   p   o    H

  p   m   u   p    f   o   e   r   u   z    i   e   s   r   o   g   n    i    t   a   e    h   r   e   v    O

  s   g   n    i   r   a   e    b    f   o   e    f    i    L    t   r   o    h    S

  p   m   u   p     m   o   r    f   e   s    i   o   n    d   n   a   n   o    i    t   a   r    b    i    V

  e    f    i    l    t   r   o    h   s   s   a    h   g   n    i    k   c   a    P

  x   o    b   g   n    i    f    f   u    t   s     m   o   r    f   e   g   a    k   a   e    L

   d   e   r    i   u   q   e   r   r   e   w   o   p   e   s   r   o    h   e   v    i   s   s   e   c   x    E

  e   m    i   r   p   s   e   s   o    l   p   m   u    P

  e   r   u   s   s   e   r    P    t   n   e    i   c    i    f    f   u   s   n    I

  y   r   e   v    i    l   e    d   e   g   r   a    h   c   s    i    d    d   e   c   u    d   e    R

  e   r   u    l    i   a    f   e   g   r   a    h   c   s    i    D

     S      N      O      T      P      M      Y      S 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 suction line  Air leaks into suction suction line  Air leaks into pump through stuffing stuffing box Foot valve too small

   S    T    L    U    A    F    E    K    A    T    N    I

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

   S    T    L    U    A    F      M    E    T    S    Y    S

Entrained air in pump. Pump hopper requires 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

   S    T    L    U    A    F    L    A    C    I    N    A    H    C    E    M

Excessive thrust caused by a mechanical failure inside the pump xcessiv xcessive e amoun amoun o u rican rican in eari earing ng ousi ousing ng causing causing ig earing earing 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 clearance at bottom of stuffing box, forcing packing into pump

Probable Faults

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Warman Base plates: Drawi ng A3-100-0 A3-100-0-1 -1981 9810 0 Suggest Suggest ed Procedure fo r Al igni ng and Grouting

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Warman Slip-on Matchi ng Flanges: Drawing A4-1 A4-11111-1-1 1-1215 21595 95

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APPENDIX A

SEAL TYPES, TYPES, PROBLEMS and SOLUTIONS

Seall Type Sea

Centrifugal

Packed Gland

Mechanical Seal

Single Stage

Single or Multi-Stage

Single or Multi-Stage

Light to Heavy Duties

Light to Super Heavy Duties

Light to Medium Duties

Low to Medium

Low

Highest

Ease of maintenance

Easiest

Difficult

Difficult

Relative seal seal lif e ranking

Medium

Shortest

Longest

Relative Rela tive l eakage eakage loss es

Low

Highest

Lowest

No

Yes

No

Worn components

Worn components

Seal face failure

 App li cat io n Gu id eli nes

Relative Cost

Dilution of Slurry Typical causes of failure

Ta Table ble A1: Comparison of shaft sealing sealing s ystems

PACKED GLAND PROBLEM  

Short packing life

 

Short sleeve life

•

•

CAUSE

 

•

 

•

 

•

 

•

Slurry exists gland

Slurry wears packing Slurry wears shaft sleeve Packing over heating and burning due to low GSW pressure

SOLUTION

 

•

 

•

 

•

Increase gland sealing water (GSW) pressure Increase GSW flowrate Loosen Gland to increase flow f low

 

•

Flow from gland too low, in worst case steam exists from gland

 

•

Pressure too high causing packing extrusion and flow restriction

 

Gland too tight

 

Packing too soft for high pressure

•

•

 

Stop, cool down, repack and then restart with correct GSW pressure and flowrate

 

Stop, cool down, repack and restart with correct GSW pressure and flow Loosen gland Review packing type Use packing retainer ring Reduce GSW pressure

•

 

•

 

•

 

•

 

•

 

•

 

•

GSW flows around outside of packing rings Too much flow from gland

 

•

 

•

 

•

 

•

Packing rings wrong size or fit-up wrong

 

•

 

•

Shaft sleeve worn Wrong size of packing Worn packing

 

•

Repack gland with correct packing Review order of assembly Disassemble and refurbish gland with new parts

Caution 1. 2.

3.

On no ac account count should the gland be loosened to such a an n extent that it disengages from the stuffing box. Putting more rings into a stuffing box when problems occur will will only be a sshort-term hort-term fix. Extra pack packing ing will exacerbate any general wear and eventually lead to excessive leakage. leakage. Corrosion by saline GSW may be minimised by the use of appropriate alloys. 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. 

Ta Table ble A2: Typical packed gland problems and solut ions 23/01/2007

 

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Runout (TIR) (TIR) (mm) {TIR = MAX – MIN reading on the Dial Gauge}

Frame

Shaft Sleeve Diameter (1) 

 A B C D E F G N P, PQ, CC

0.10 0.10 0.12 0.12 0.15 0.15 0.17 0.10 0.12

0.15 0.16 0.18 0.24 0.38 (2)  0.43 (2)  0.52 (2)  0.17 0.19

0.15 0.16 0.18 0.21 0.28 0.33 0.38 0.17 0.19

Q, QR, DD R, RS, EE S, ST, FF T, TU, GG H U

0.12 0.15 0.15 0.17 0.17 0.20

0.25 0.30 (2)  0.31 (2)  0.35 (2)  0.37 (2)  0.39 (2) 

0.23 0.26 0.31 0.35 0.37 0.39

(1)

Frame Plate Plate Spigot Bore Face

Halve these values for shaft without the shaft sleeve (2) Flowserve (Durametallic) (Durametallic) seal: 0.25 mm

 Application: 1. All W Warman arman pu pumps mps up to normal normal max maximum imum speed speed 2. single stage pumps 3. New and o old ld pumps – di dimensions mensions to be checked and adjusted to be within within the tolerances provided 4. Majority of mechanical seal types 5. range Bearing a assemblies ssemblies w with ith Fitted End End Play within the the normal Warman Warman recomme recommended nded

Ta Table ble A3: Typical maximum allowable misalignment values for mechanical seals seals

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MECHANICAL SEAL PROBLEM  

•

Infant or catastrophic failure

CAUSE

 

Seal faces cracked, chipped or broken Dry running – faces cracked or scored Misalignment of sealing faces Pressure x velocity too high Spring failure Seal springs clogged and inoperative Seal faces over-compressed

 

Seal faces cracked

 

Seal faces worn, scored or misaligned

 

•

 

•

 

•

 

•

 

•

 

•

•

 

•

Seal leakage

•

•

SOLUTION

Review and revise installation and/or operating conditions   Recondition seal by replacing failed parts   Change seal specification or materials    Add flush or throttling throttling bush to reduce contaminants reaching the seal  

•

•

•

•

  Review

•

 

•

and revise installation and/or operating conditions Replace worn seal faces, O-ring or secondary seals

•

   

•

 

•

Contaminated barrier fluid

 

•

O-ring leaking Secondary seal worn or cracked Seal faces cracked or worn

 

Relap seal faces

 

Review and revise installation and/or operating conditions Reduce TDS of barrier fluid Reduce variations in operating conditions Change to harder face material

•

•

 

•

 

•

Short seal Life

 

Operating pressure or temperature above seal rating Wear of seal body Failure or seal face drive pins

 

Worn seal faces

 

•

 

•

•

•

 

•

 

•

Caution

1. Mechanical seals require a controlled and stable environment to ensure long and reliable operation. 2. The seal manufa manufacturers cturers operating operating and maintenance maintenance instructions instructions / procedures must be strictly adhered too. Note that these t hese instructions may include torque settings for the mechanic mechanical al seal locking collar. 3. The mechanic mechanical al seal warranty will most likely be voided voided if a failed seal has been subjected subjected to dry running, water hammer, low suction pressures or high suction lifts, cavitation, excess vibration, thermal shock, reverse rotation or dead-heading / low-flow conditions that are

linked to its failure. 4. Prior to operating for the first time, the mechanical seal setting tabs must be removed   and any flush or quench liquid connections checked that they will supply the required flow and pressure. Access to the mechanical seal is obtained by first removing the seal guard. 5. It is normally rec recommended ommended that impellers impellers without backvanes backvanes are are used for mechanical mechanical seals to reduce the flow and turbulence wear in the seal chamber. Ta Table ble A4: Typical mechanical seal problems and sol utions

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 A s s emb  As em b l y & Main Mai n t enan en anc ce Instructions Suppl up ple ement ‘P3’ ‘P3’ Series Se ries ‘A’ ‘A ’ Slurry Pumps Types ‘AH’ & ‘M’

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© Weir Minerals Australia Ltd 2007. Weir Minerals Australia Ltd 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 an y form or by any means, without the prior written consent of  Weir Minerals Australia  Australia Ltd.

 

Office of origin :

Pump Technology Centre, Artarmon

Reference :

Pump Manuals

Date :

23 January 2007

Last Issued:

July 2005

 

Weir Minerals

| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Warnings Personnel injury and / or equipment damage could result from not observing the following IMPORTANT SAFETY INFORMATION.    A 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, mechanical seals, etc) all related safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment   and maintenance.    All guards  for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards should not be removed or opened while the pump is running. Personal injury may result from contact with rotating parts, seal leakage or spray.   Driver rotation must b e checked checked  before belts or couplings are connected.   Pumps must not be operated 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 high temperature and pressure created.   Pumps must be used only within their allowable limits  of pressure, temperature and speed. These limits are dependent on the pump type, configuration and materials used.   Do not apply heat heat to t he 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.   •

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LIFTING of components •

  lifting TappedIndividual holes (forparts eye bolts) only . and lugs (for lifting shackles) on Warman pumps are for only.

  Lifting devices devices of adequate adequate capacity capacity must be used used wherever wherever they are are required to be used.   Safe workshop practices should be applied during all assembly and maintenance work.   Personnel must never work under suspended loads.   The pump must be fully isolated   before any maintenance work, 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.   •

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Castings   made from materials listed are brittle and have low thermal shock resistance.

 Attempts to repair or rebuild by welding may cause catastrophic catastrophic failure. Repairs of such castings using these methods must not be attempted - A03, A04, A05, A06, A07, A08, A09,  A12, A14, A49, A51, A52, A53, A53, A61, A210, A211, A217, A217, A218, A509.   Impellers  must be tight t ight on the shaft before any start-up, ie all components on the shaft between the impeller and the pump end bearing must butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to •

unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking etc.   Burning  of elastomer pump components will cause emission of toxic fumes and result in air pollution which could lead to personnel injury.   Leakage from the pump shaft seals and/or leakage from worn pump components or seals may cause water and/or soil contamination. contamination.   Liquid waste disposal  from servicing of pumps or stagnant water from pumps stored for long periods, may cause water and/or soil contamination.   Do not apply anti-seize compounds   to the impeller or shaft threads or to elastomer seals during assembly. Anti-seize can greatly reduce the impeller thread friction and may cause the impeller to loosen during pump shut-down and run-back resulting in pump damage, or the elastomer seals to leak at reduced pressure.   This manual applies only to genuine Warman parts  and Warman recommended parts.   Mixing of new and worn pump parts  may increase the incidence of premature pump wear and leakage.   Large foreign objects or tramp  entering a pump will increase the incidence of higher wear and / or damage to the pump. Routine inspection and maintenance of mill trommel screens will assist to reduce the danger of grinding balls entering a mill discharge pump.   Large variations in slurry properties may lead to accelerated rates of wear and corrosion of pump components eg   Wear increases exponentially exponentia lly with velocity and slurry particle size.   Corrosion rate doubles for every 10 degree Celsius increase in slurry temperature. temperature .   Corrosion rate increases exponentially exponentiall y as slurry pH decreases. •

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Weir Minerals

| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

 

ISSUED: JA NUARY 2007

LA ST ISSUE: JULY 2005

WARMAN PUMPS

 ASSEMBLY AND MAINTENANCE MAINTENANCE INSTRU INSTRUCTIONS CTIONS SUPPLEMENT SUPPLEMEN T ‘‘P3’ P3’

SLURRY PUMPS TYPE 'AH' & ‘M’

CONTENTS WARNINGS

2 

CONTENTS

4 

1 

6 

INTRODUCTION  Ad vant ages and Uses of Series Seri es ‘ A’ Type ' AH' & ' M' Slur Sl ur ry Pumps Pum ps

6 

Bearing Assembly – Ma Maintenance intenance & Assembly Instru ctio ns

6 

Centrifug al Sea Sealing ling - Lubr ication

6 

Pa Parts rts Ide Identification ntification

7 

2   ASSEMB  ASSEMBLY LY INSTRUCTIONS

7 

Frame Assembly

8

8 

Fitting Bearing Assembly to Base - See Figures 1 & 6 Pump Assembl y

9

9 

Fitting Frame Plate and Cover Plate Bolts - See Figure 2 Seall Assembl y Sea

11

11  17  24 

Gland Assembly Centrifugal Seal Assembly Warman Mechanical Seal Assembly Pump Assembl y

24

Metal Liners - Two Piece Metal Liners - Three Piece Elastomer Liners - Two Piece Elastomer Liners - Three Piece Elastomer Liners - Four Piece  Assembled Pump: Pump: Fitting Joint Ri Rings ngs - See Figure 12 Impeller Adjustment - See Figures 13 & 6

26  29  32  34  37  40  41 

3 

PUMP DISMANTLING & IMPELLER IMPELL ER REMOVAL

42 

4 

PRODUCT MODIFICATION ADVICE (PMA)

43  46 

BASIC BA SIC PART NUMBERS NUMBERS & PARTS LIST

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 APPENDIX

48 

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1

| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

INTRODUCTION Supplement 'P3' 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

M4 - Warman Mechanical Seals BA1, BA2, BA3 or BA4 - One of these depending on whether Heavy Duty, Basic,

Modified Basic or Oil Filled Bearing Assemblies are used respectively.

 Ad van tag es and an d Us es of o f Ser ies ‘A ’ Ty pe 'AH' ' AH' & ' M' Slur Sl ur ry Pumps Pum ps Designed for the continuous continuous pumping of highly abrasive abrasive and/or corrosive slu slurries. rries. These pumps feature a wide choice of replaceable hard metal or pressure moulded elastomer liners and impellers and are all interchangeable interchangeable within the same casing. The Warman centrifugal shaft seal is commonly used, but an interchangeable packed gland seal is also available for every pump. Special mechanical seals for slurry service are being developed. Ease of maintenance features include:      

•

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Through bolt design Minimum number of casing bolts Slip fit replaceable replaceable Shaft sleeve Cartridge type Bearing Assembly Cast in Impeller thread Replaceable liners are positively attached Impeller Release Collar on large models

Bearing Assembly – Maintenance Maintenance & Assembly Instruct ions The bearing assembly is assembled and maintained according to the instructions contained in the respective Warman Supplement Supplement 'BA1' to 'BA4' according to the TYPE of bearing assembly utilised.

Centrif Ce ntrif ugal Sealing Sealing - Lubri cation In centrifugally sealed pumps, lubricate the static seal chamber sparingly but regularly, by means of the grease cup. The grease for the centrifugally sealed pump static seal chamber should have the following specifications: specifications:  A lithium complex soap soap thickener grease with EP additives additives and oxidation oxidation inhibitors inhibitors.. N.L.G.I. Consistency No Drop Point

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2

260 °C

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Work penetration 25°C A.S.T.M.

265 - 295

RECOMMENDED RECOMMEND ED GREASE: MOBIL HP or equivalent.

Parts Pa rts Identific ation The comments 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. The relevant relevant Warman Basic Basic Numbers Numbers are listed at the end of this supplement.

In all correspondence with Weir Warman Ltd, 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 misunderstanding s or wrong deliveries. When in doubt, the pump serial number should be quoted as well.

2

ASSEMB ASSEMBLY LY INSTRUCT INSTRUCTIONS IONS  A Components Diagram of the particular pump being assembled will assist in following the pump assembly instruction steps as detailed in the following sections. 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 repainted where required. Mating faces and spigots should be free of rust, dirt and burrs and given a coat of grease before they are fitted together t ogether to assist future overhaul. It is preferable to renew small bolts and set screws during overhaul and all threads should be coated with with graphite grease be before fore assembly. It is also recommended 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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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Frame Assembly

Page 7 of 48

Figure 1

Fitting Bea Bearing ring A ssembly t o Base - Se See e Figures 1 & 6

1.

Insert ADJUSTING SCREW (001) in BASE (003) from outside. Screw on one nut and fully tighten. Screw two add additional itional nuts with two flat wash washers ers in between. These nuts to be left looseon and maximum distance apart.

2.

Apply grease to machined surfaces (bearing housing support cradle) in base.

3.

Lower BEARING ASSEMBLY (005) into base. Approximate Approximately ly match machined surfaces of the housing with surfaces in the base. Check that the bearing housing lug has fitted over the adjusting screw in the base and is also between the nuts and washers.  Fit CLAMP BOLTS (012) (012) through base fro from m underne underneath. ath. Drop CLAMP WASHER (011) (011) over each bolt (domed side side up) and screw on nuts. Fully tighten clamp bolts on side 'A', ie. on left hand side of base when looking from impeller end refer to Figures Figures 1 and 6. The bolts on the opposite opposite side 'B' should not be tightened for the time time being. Leave snug snug only, to maintain alignment alignment but allow axial movement.

4.

Grease SHAFT (073) protruding from LABYRINTH (062) at impeller end. This application of grease will assist fitting and removal of shaft components and prevent damage by moisture to the shaft.

5.

Fit two two pieces pieces of timber timber to underside of base base or ap appropriate propriate assembly cradle to prevent the pump from tipping forward during assembly of the wet end.

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Check the base is at a sufficient height from the floor to allow assembly of the wet endthat components.

Pump Assembly

Figure 2

Fitti ng Frame Plate and Cover Plate Bolts - See See Figure 2

1.

Fit FRAME FRAME PLATE (032) to base, base, making certain that the frame plate spigot has engaged with the corresponding base recess. Grease the recess to assist in future removal. With large pumps, frame plates are provided with radially tapped holes for EYE BOLTS (-) to facilitate lifting.

2.

Insert FRAME PLATE STUDS (039) or FRAME PLATE BOLTS (034), depending on the pump. pump. Fit nuts and fully tighten. In some pumps the the frame plate is bolted ex externally ternally (studs are are used). In other pumps, bolts are used and are inserted from the frame plate. The frame plate be rotated provide eight discharge the exception of can B frame pumpstoand the 3/2 AH alternate pump, where only 4positions positionswith are available.

Rubber Lined Pumps:

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Fit COVER PLATE BOLTS (015) through frame plate lugs, screw on nuts, and torque evenly all bolts to value given in Table 1. Metal Me tal Lin ed Pumps:  

Fit only COVER PLATE BOLTS (015) that will not   be used to engage with lugs on outside of metal VOLUTE LINER (110) {check metal volute for position of lugs} through frame plate lugs, screw on nuts and torque evenly all bolts to value given in Table 1. Note: Some pumps are are fitted with KEEPER PLATES (081) that fit onto th the e cover plate bolt and engage with the lugs on metal volutes. volutes. This applies to the 6/4 AH, AH, 8/6 AH, 10/8 M and 12/10 M pumps respectively. respectively. These cover cover plate bolts will be fitted later. TABL E 1 - COVER PLA PLATE TE BOLT TORQUE TORQUES S PUMP

MAXIMUM TORQUE (Nm)

1.5/1 AH

50

2/1.5 AH

50

3/2 AH

50

4/3 AH

110

6/4 AH

220

8/6 AH

220

10/8 AH

570

12/10 AH

570

14/12 AH

950

16/14 AH

1500

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20/18 AH

1500

10/8 M

220

12/10 M

220

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Seal Se al As sembly

Figure 3

Gland Gla nd Assembly

Fitting Stuffing Box, Lantern Restrictor, (or Neck and Lantern Rings), Packing, Gland, Shaft Sleeve, Shaft Spacer and Shaft Sleeve O-Rings - See Figure 3 and 7 Gland arrangements for stuffing boxes are shown on Warman drawing A4-110-0-115795 attached. Select the the arrangement arrangement that best best suits the pum pump p application. application. Non-metallic LANTERN RESTRICTORS (118-1) offer the advantage of minimising the gland sealing water requirements. requirements.

Two methods are described below for assembling the gland depending on the size of the frame. Either method can be used if it is found found to be more suitable. suitable. Figure 3 illustrates the relative position of impeller release collars, sleeves, shaft sleeves, O-Rings O-Rings etc on the shaft. The particular arrangement arrangement of these components components can vary from one pump to another. Table 2 lists components which are as assembled sembled onto the shaft in the order in which they are fitted, commencing at the LABYRINTH (062) at the pump end of the bearing assembly. Pumps with similar arrangements are grouped together. Generally the modified basic frames (CC, DD etc) etc) will have the same same shaft components as the basic frames (B, C, D, etc).

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

TABLE 2 - GLAND SEAL FRAME

PUMP

SHAFT COMPONENTS (in

order from Labyrinth to Impeller)  G

16/14 G-AH

109 Shaft O-Ring 076 Shaft Sleeve (long) 109 Shaft O-Ring

NP R RS

3/2 NP-AH, 8/6 R-AH 10/8 R-M & 12/10 R-M 12/10 RS-M

109 Shaft O-Ring 076 Shaft Sleeve (long) 064 Impeller O-Ring

B C

1.5/1 B-AH & 1.5/1 N-AH 2/1.5 B-AH & 2/1.5 N-AH

109 Shaft O-Ring 075 Shaft Sleeve

N P

3/2 C-AH & 3/2 P-AH

109 Shaft O-Ring 117 Shaft Spacer 217 Impeller O-Ring

C

4/3 C-AH & 4/3 P-AH

109 Shaft O-Ring

D E

4/3 D-AH & 4/3 Q-AH 10/8 E-M & 12/10 E-M

075 Shaft Sleeve 109 Shaft O-Ring

P Q

6/4 E-AH 8/6 E-AH

117 Shaft Spacer 064 Impeller O-Ring

D

6/4 D-AH & 6/4 Q-AH

109 Shaft O-Ring

F G

8/6 F-AH 10/8 F-M & 12/10 F-M

075 Shaft Sleeve 109 Shaft O-Ring

Q

10/8 G-AH & 12/10 G-AH 14/12 G-AH

117 Shaft Spacer 109 Shaft O-Ring

G

20/18 G-AH & 20/18 TU-AH

109 Shaft O-Ring

TU

239 Impeller Release Collar 109 Shaft O-Ring 076 Shaft Sleeve (long) 109 Shaft O-Ring

TU

16/14 TU-AH

109 Shaft O-Ring 239 Impeller Release Collar 109 Shaft O-Ring 076 Shaft Sleeve (long)

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

FRAME

PUMP

SHAFT COMPONENTS (in order from Labyrinth to Impeller)

064 Impeller O-Ring ST

10/8 ST-AH

210 Shaft O-Ring

12/10 ST-AH

239 Impeller Release Collar

14/12 ST-AH

210 Shaft O-Ring 076 Shaft Sleeve (long) 210 Shaft O-Ring

H

16/14 H-AH

109 Shaft O-Ring 239 Impeller Release Collar 109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring 117 Shaft Spacer 064 Impeller O-Ring

T

10/8 T-AH

109 Shaft O-Ring

12/10 T-AH

239 Impeller Release Collar

14/12 T-AH

109 Shaft O-Ring 179 Shaft Sleeve Spacer 109 Shaft O-Ring 076 Shaft Sleeve (long) 109 Shaft O-Ring

F

10/8 F-AH 12/10 F-AH

109 Shaft O-Ring 239 Impeller Release Collar

14/12 F-AH

109 Shaft O-Ring 075 Shaft Sleeve FAM117 Shaft Spacer G109 Shaft O-Ring G117 Shaft Spacer G109 Shaft O-Ring

FRAMES: B, C, D, E, F, CC, DD, EE, FF, NP, P, PQ, Q, QR, R, RS & S

1.

Place STUFFING BOX (078) flat on bench (gland side up).

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2.

Place a LANTERN RESTRICTOR (118) (small diameter down) in gland recess to rest on retaining lip. In some applications, applications, a NECK RING (067) is used in place of the lantern restrictor.

3.

Stand SHAFT SLEEVE (075 or 076) on end and slide through lantern restrictor.

4.

Fit following items in turn: (a) 

First PACKING RING (111) of correct length to fill an annulus; nulus;

(b) 

Remaining packing rings (stagger packing joints) to alm almost ost com completely pletely fill the annulus. Flatten each one separately. separately. Note:   When a neck ring is used, place LANTERN RING (063) on top of first

ring of packing and press down to flatten first ring; then fit remaining packing rings (stagger packing joints). 5.

Assemble GLAND (044) halves, insert GLAND CLAMP BOLTS (126) and fully tighten. Place gland in stuffing box and push down to compress packing rings. Insert GLAND BOLTS (045) and just nip up nuts sufficiently to hold shaft sleeve (final adjustment will be made when testing pump).

6.

From the pump components diagram or from Table 2 (for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and SHAFT SLEEVE (075 or 07 076). 6). Fit these ccomponents omponents to the shaft. Instructions for fitting an IMPELLER RELEASE COLLAR (239) are contained in Warman Supplement 'M2'.

7.

Insert assembled stuffing box in frame plate and tap iinto nto position with a m mallet. allet. Locate stuffing box with water connection connection at top. For the bigger frame frames, s, assembly of the stuffing box into the frame plate is best carried out using LIFTING PLATE (310) refer to Figure 7. The shaft sleeve will probably remain forward. It should be pushed back to the mating part on the shaft. Check that any O-rings are correctly positioned in grooves.

8.

Fit remaining O-rings and shaft spacers as per Table 2. Note:   (c)  (d) 

9.

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To as assist sist in in holding holding the last O-ring in position position which seals against the Impe Impeller, ller, apply heavy grease to the O-ring groove. All the O-rings O-rings in their respective respective grooves will be compressed compressed and fully covered by these metallic parts when the impeller is screwed onto the shaft.

Liberally grease shaft thread.

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

FRAMES: G, GG, H, ST, T, TU & U

1.

From a components components diagram or from Table 2 ((for for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and IMPELLER (-). Fit these these components components to the shaft. Instructions for fifitting tting IMPELLER RELEASE COLLAR (239) are contained in Warman Supplement 'M2'

Note:   (a) To assist in holding the last O-ring in position which seals against the impeller,

apply heavy grease to the O-ring groove. (b) All the O-rings in their respective grooves will be compressed and fully covered

by these metallic parts when the impeller is screwed onto the shaft. 2.

Fit LANTERN RESTRICTOR (118) (small diameter out) freely over shaft and push against bearing housing. In some cases a LANTERN RING (063) followed by NECK RING (067) is used in place of the t he lantern restrictor.

3.

Attach STUFFING BOX LIFTING PLATE (310) to STUFFING BOX (078) on opposite side of lugs using three jacking screws provided and ensure that water connection in the stuffing box is in line with the lifting beam see Figure 7.

4.

Lift stuffing stuffing box with lifting plate by means means of a hoist and insert insert stuffing box box in frame plate, tap in position with mallet.

5.

Fit CLAMP BRACKET (022) using CLAMP BRACKET SET SCREW to temporary secure the stuffing box into the frame plate during subsequent assembly procedures.

6.

Assembly of all gland parts in stuffing stuffing box should be carried out in the fo following llowing manner after all other parts of the pump have been assembled. (a) 

Slide LANTERN RESTRICTOR (118) or NECK RING (067) inside stuffing box against retaining lip.

(b) 

Fit first PACKING RING (111) of correct correct length length to fill annu annulus lus and and push push against neck ring.

(c) 

Slide LANTERN RING (063) and press to flatten first ring. When a lantern restrictor is used, the lantern ring is omitted.

(d) 

Fit packing packing rings to almost almost completely completely fill the annulus (stagger packing joints

(e) 

7.

and flatten each ring). Assemble GLAND (044) halves over shaft sleeve sleeve with gland spigot towards stuffing box, insert insert GLAND CLAMP BOLTS BOLTS (126) and fully fully tighten. Push into stuffing box to compress compress packing rrings. ings. Insert GLAND BOLTS (0 (045) 45) and nip up. Final adjustment adjustment will be made when testing the pump.

Alternatively it is possible to fit fit the shaft sleeve and the gland parts into the stuffing box and then fit this sub-assembly sub-assembly into into the frame plate. Caution has to b be e given not to allow the shaft sleeve to fall out during fitup.

8.

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Page 15 of 48

Figure 4a

Figure 4b 23/01/2007

 

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Centrifug Ce ntrifug al Seal Seal A ssembly

[METAL (029) OR ELASTOMER (029R) EXPELLER RING]

Page 16 of 48

Fitting Expeller Ring, Neck and Lantern Rings, Packing, Shaft Sleeve, Shaft Sleeve ORings and Expeller - See Figures 4a, 4b and 7 For high seal (HS) expeller assemblies refer to Warman Manual Supplement M8. Two types of expeller ring are available - metal or elastomer. Metal expeller rings are generally fitted with packing. Elastomer expeller rings are recommended to be fitted with LIP SEALS ONLY   as

there is no provision for lubrication, and the elastomer cannot conduct heat away that would be generated by packing. Different methods are described below for assembling the centrifugal seal, depending on the size of the pump or pump frame. Either method can be used if it is found to be more suitable. Figures 4a and 4b illustrate the relative position of impeller release collar, sleeves, shaft sleeves, O-rings O-rings etc on the shaft. The particular arrang arrangement ement of these components vary from one pump to another. Table 2 lists components for a gland sealed sealed pump which are assembled onto the shaft in the order in which they are fitted commencing at the LABYRINTH (062) (062) at the pump pump end of the bearing bearing assembly. assembly. Pumps with similar arrangements are are grouped together. Generally the modified basic basic frames (CC, DD etc) will have the same shaft components as the basic frames (B, C, D, etc). In most cases, the EXPELLER (028) substitutes directly for the SHAFT SPACER (117) in the gland sealed arrangement. arrangement. All other sleeves/O-Rings sleeves/O-Rings etc remain the same same.. Some exceptions to the above are listed in Table 3. 

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

TABL E 3 - CENTRIF CENTRIFUGAL UGAL SEAL FRAM E

PUMP

SHAFT COMPONENTS (in order from Labyrin th to Impelle Impeller) r)

D

6/4 D-AH

109 Shaft O-Ring

F Q

8/6 F-AH 6/4 Q-AH

075 Shaft Sleeve 109 Shaft O-Ring

028 Expeller 064 Impeller O-Ring or 109 Shaft O-Ring C

4/3 C-AH

109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring CAM117E Shaft Spacer 109 Shaft Spacer O-Ring D028 Expeller 064 Impeller O-Ring

E R RS

8/6 E-AH & 8/6 R-AH 10/8 E-M & 10/8 R-M 12/10 E-M & 12/10 R-M

109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring

12/10 RS-M

EAM117E Shaft Spacer F109 Shaft Spacer O-Ring F028 Expeller 109 Shaft O-Ring

G

16/14 G-AH

109 Shaft O-Ring

TU

20/18 G-AH & 20/18 TU-AH

239 Impeller Release Collar 109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring 028 Expeller 109 Shaft O-Ring

TU

16/14 TU-AH

109 Shaft O-Ring 239 Impeller Release Collar 109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring 028 Expeller 064 Impeller O-Ring

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FRAM E

PUMP

SHAFT COMPONENTS (in order from Labyrin th to Impelle Impeller) r)

T

10/8 T-AH 12/10 T-AH

109 Shaft O-Ring 239 Impeller Release Collar 109 Shaft O-Ring 179 Shaft Sleeve Spacer 109 Shaft O-Ring 075 Shaft Sleeve 109 Shaft O-Ring 028 Expeller

109 Shaft O-Ring ST

10/8 ST-AH

210 Shaft O-Ring

12/10 ST-AH 14/12 ST-AH

239 Impeller Release Collar 210 Shaft O-Ring 075 Shaft Sleeve 210 Shaft O-Ring 028 Expeller 210 Shaft O-Ring

Metal Expeller Ring (029) - Figure 4a

To fit PACKING (111) to metal expeller rings, follow the instructions below dependin depending g on the size of the pump frame: FRAMES: B, C, D, E, F, CC, DD, EE, FF, NP, P, PQ, Q, Q, QR, R, RS & S 1.

Place EXPELLER RING (029) flat on bench (gland side up).

2.

Drop NECK RING (067) into gland recess as retaining lip.

3.

Stand SHAFT SLEEVE (075) on end through neck ring.

4.

Fit the following items in turn:

5.

(a) 

First PACKING RING (111) of correct length to fill a annulus. nnulus.

(b) 

LANTERN RING (063) pressed down to flatten first ring.

(c) 

Remaining packing rings (stagger packing joints and flatte flatten n each ring) to almost completely fill the annulus.

Assemble GLAND (044) halves, insert GLAND CLAMP BOLTS (126) and fully tighten. Place gland in expeller ring and push down to compress packing rings. Insert GLAND BOLTS (045) and just nip up nuts sufficiently to hold shaft sleeve (final adjustment will be made when testing the pump).

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6.

From a components diagram or from Tables 2 and 3 (for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and SHAFT SLEEVE (075). Fit these components to the sh shaft. aft. Instructions for fitting an IMPELLER RELEASE COLLAR (239) are contained in Warman Supplement 'M2'.

7.

Insert assembled expeller ring in frame plate and tap in position with mallet. Locate expeller ring ring with grease grease inlet at top. top. Assembly of of the  expeller ring into the frame plate is best carried out using LIFTING PLATE (310) - refer to Figure 7.

8.

The shaft sleeve will probably remain forward. It should be pushed back to the mating part on the shaft. Check that any O-rings are correctly positioned in grooves.

9.

Assemble remaining O-rings and shaft spacers as per Tables 2 and 3 onto shaft which fit between SHAFT SLEEVE (075) ( 075) and EXPELLER (028).

10.

Place EXPELLER EXPELLER (028) (028) on shaft and and press press up to mating part on shaft.

11.

Fit remaining remaining O-RING (109 or or 064) 064) to groove on ex expeller. peller. Note: (a) 

To assist assist in in holding holding the last O-ring in position position which seals against the Impe Impeller, ller, apply heavy grease to the O-ring groove.

(b) 

All the O-rings O-rings in their respective respective grooves will be compressed compressed and fully covered by these metallic parts when the impeller is screwed onto the shaft.

12.

Liberally grease shaft thread.

13.

Assembly of gland lubricating lubricating parts parts will be done after all other p parts arts of the pump have been assembled.

14.

Fit GREASE CUP ADAPTOR GREASE CUP (-)lantern to expeller expeller Fillcup. ccup up with recommended grease and(138) screwand down cup to charge ring. ring. Top up

FRAMES: G, GG, H, H, ST, T, TU, & U 1.

From a components diagram or from Tables 2 and 3 (for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and EXPELLER (028). Fit these components to the shaft. Instructions for fitting an IMPELLER RELEASE COLLAR (239) are contained in Warman Supplement 'M2'.

2.

Fit LANTERN RING (063) followed by NECK RING (067) freely over sleeves and push both against bearing housing.

3.

Attach EXPELLER RING LIFTING BEAM (310) to EXPELLER RING (029) on opposite side of lugs using three jacking screws provided and ensure that the grease inlet in the expeller ring is in line with the lifting lif ting beam refer to Figure 7.

4.

Lift expeller expeller ring with lifting beam by means of a hoist and insert expeller ring in frame plate, plate, tap in position position with mallet. Grease location location recess recess to as assist sist later removal.

5.

Assembly of all gland parts in expeller ring will be carried carried out in the following manner after all other parts of the pump have been assembled.

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(a)

Slide NECK RING (067) inside expeller ring against retaining lip.

(b)

Fit first PACKING RING RING (111) (111) of correct length to fill annulu annuluss and push a against gainst neck ring.

(c)

Slide LANTERN RING (063) and press to flatten first ring.

(d)

Fit remaining remaining packing packing rings to almost completely fill the an annulus nulus - stagger packing joints and flatten each ring.

(e)

Assemble GLAND (044) halves over shaft sleeve sleeve with gland spigot towards expeller ring, insert insert GLAND CLAMP BOLTS (126) and and fully tighten. Push into expeller ring to compress packing packing rings. Insert GLAND BOLTS (045) (045) and nip up. (Final adjustment will be made when testing pump).

(f)

Fit GREASE CUP ADAPTOR (138) and GREASE CUP (-) to expeller ring. Fill cup with recommended grease and screw down cup to charge lantern ring. Top up cup.

6.

Assemble remaining O-rings and shaft spacers spacers as per Table 2 and Table 3 onto shaft which fit between SHAFT SLEEVE (075) and EXPELLER (028).

7.

Place EXPELLER (028) on shaft and press up to mating part on shaft.

8.

Fit remaining O-RING (109 or 064) to groove on expeller. Note:  

(a)

To assist assist in holding the last last O-ring in position position w which hich seals seals a against gainst the impe impeller, ller,

apply heavy grease to the O-ring groove. (b)

9.

All the O-rings in their respective grooves will be compressed and fully covered by these metallic parts when the impeller is screwed onto the shaft.

Liberally grease shaft thread.

Elastom er Expeller Rin g (029R) (029R) - Figur Figur e 4B

To fit LIP SEALS (090) to ELASTOMER EXPELLER RINGS (029R) follow instructions below depending on the pump size: FOR 1.5/1 AH, 2/1.5 AH, 3/2 AH and 4/3 AH PUMPS: These pumps do not use expeller ring studs or lip seal glands. The seals are reduced to two in number and are retained by the design of the expeller ring. 1.

Place EXPELLER RING (029R) flat on on bench bench {gland side down} and fit two LIP SEALS (090) into the bore of of the expeller ring. The seals will fit only from from the 'wet' side of the expeller ring. Liquid soap or rubber lubricant will ease fitting. fitting .

Continue assembly from point 5 below:OTHER PUMP SIZES: 1.

Place EXPELLER RING (029R) flat on bench {gland side up}.

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2.

Fit two EXPELLER RING STUDS (079) in expeller ring tapped holes provided and fully tighten.

3.

Insert two LIP SEALS (090) {lip down} in gland recess against retaining lip. Lips to point INTO pump so they are are activated by internal pressure. pressure. To ease fitting smear outside diameter of seals with liquid soap soap or rubber lubricant. Note that LANTERN RING (063R) is used ONLY on 10/8, 12/10 and 14/12 AH pumps.

4.

Place LIP SEAL SEAL GLAND GLAND (241) in expeller ring, fit nu nuts ts to sstuds tuds and fully tighten. (Gland adjustment is not required).

 AL L PUMP SIZES: 1.

From a components diagram or from Tables 2 a and nd 3 ((for for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and SHAFT SLEEVE (075). Fit these components to the sh shaft. aft. Instructions for fitting an IMPELLER RELEASE COLLAR (239) are contained in Warman Supplement 'M2'.

2.

Insert assembled assembled expeller expeller ring over shaft sleeve into frame plate and tap in position with mallet. Locate expeller expeller ring with studs on horizontal horizontal plane. The shaft sleeve will probably remain remain forward. It should be pushed back to the mating part on the the shaft. Check that any O-rings are correctly position positioned ed in grooves.

3.

Assemble remaining O-rings and shaft spacers as per Tables 2 and 3 onto shaft which fit between SHAFT SLEEVE (075) ( 075) and EXPELLER (028).

4.

Place EXPELLER (028) on shaft and press up to mating part on shaft.

5.

Fit remaining O-RING (109 or 064) to groove on expeller. Note:  

(a)

To assist assist in holding the last O-ring in position which sseals eals aga against inst the impeller, apply heavy grease to the O-ring groove.

(b)

All the O-rings in their respective grooves will be compressed and fully covered by these metallic parts when the impeller is screwed onto the shaft.

6.

Liberally grease shaft thread.

Warman Mechanical Seal Assembly

For pumps fitted with a Warman Mechanical Seal (Warman Basic Number '162-50') follow the assembly and maintenance instructions contained in Warman Supplement 'M4' . The Warman Mechanical Seal is supplied as a cartridge seal ready to install in the pump. If the mechanical seal is in pieces, first assemble assemble the components into a cartridge cartridge following the instructions in Warman Supplement 'M4'. Note: When fitting Warman Mechanical Seals the BEARING ASSEMBLY (005) needs to be altered. Replace END COVER COVER (024) at pump pump end of Bearing As Assembly sembly with END COVER (024-50) by following instruction contained in Warman Supplement 'M4'.

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Pump Assembly Depending on the TYPE OF LINERS being fitted - METAL or ELASTOMER, check Table 4 foris the relevant section for instructions on completing pump assembly (Note: liner fit-up same regardless of frame used). Metal and elastomer liners can be used interchangeably (depending on the final application). A mix of metal and elastomer elastomer liners is also also possible. possible. In these cas cases es follow the relevant instructions in the various sections as per Table 4 depending on the combination used. TABL E 4 - PUMP FIT-UP: FIT-UP: CASING CA SING LINERS METAL LINERS PUMP

TWO PIECE

ELASTOMER LINERS

THREE PIECE

TWO PIECE

 

--

•

 

--

•

   

1.5/1 AH

•

2/1.5 AH

•

THREE PIECE

FOUR PIECE

 

--

--

 

--

--

   

•

---

---

 

--

•

 

--

 

--

•

 

--

 

--

•

 

--

 

--

•

 

--

 

--

--

•

 

--

--

•

 

--

--

•

 

--

•

--

 

--

--

•

3/2 AH 4/3 AH

•

---

6/4 AH

--

•

8/6 AH

--

•

10/8 AH

--

•

12/10 AH

--

•

14/12 AH

--

•

16/14 AH

--

•

20/18 AH

--

•

10/8 M

--

•

12/10 M

--

•

•

•

 

 = Denotes Standard Liner Fit-up (Same regardless of FRAME used) 

•

 

 

 

 

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Figure 5

Two Piece Meta Metall Liners

Page 23 of 48

Figure 6

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Figure 7

Metal Liners - Two Piece

Fitting Seal Ring, Frame Plate Liner Insert, Volute Liner Seals, Volute Liner, Impeller and Cover Plate - See Figures 5, 6 and 7 For two piece metal lined pumps, the volute liner and 'front liner' (throatbush) are one s izes 1.5/1 AH, 2/1.5 AH, 3/2 AH and 4/3 AH. piece. This applies for pum p sizes 1.

Fit 'C'-section SEAL RING (122) onto rim of stuffing box or expeller ring. To aid in holding the seal in position during subsequent assembly steps, it is recommended that the seal be cemented to the stuffing box/expeller ring using rubber cement, and preferably of the dry contact type, with sufficient drying time allowed before contacting the two parts parts - as per the manufacturers manufacturers instruc instructions. tions. Furthermore, the cement should only be applied at 4 to 6 'spots' on bottom of the 'C'-section in seal rather than all the way way around. This will ensure ensure the Seal is not unduly restrained restrained during compression.

2.

Fit VOLUTE LINER SEAL (124 or 125): The seal is one of two types: O-ring: VOLUTE FRAME SEAL (125):  1.5/1 AH, 2/1.5 AH and 3/2 AH pumps:

The seal is an O-ring - it is fitted at a later stage (refer to 3 (c) below) 'C'-SECTION: 'C'-SECTIO N: VOLUTE LINER SEAL (124) (124):: 4/3 AH Pump .

The seal is a 'C'-section 'C'-section and it is activated by interna internall pressure. Fit it (flat face in) into the frame plate groove. groove. Use rubber contact contact cement if required.

3.

Fit FRAME PLATE LINER INSERT (041) and IMPELLER (-).

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Where applicable fit the FRAME PLATE LINERS STUDS (026) Note: Some frame plate liner insert are not held with studs and are held only by a spigot on the insert engaging with the frame plate or by the volute liner. For 1.5/1 AH, 2/1.5 2/1.5 AH and 3/2 AH Pum ps ps.. (a) 

Obtain correct type of IMPELLER (-) as specified for the p particular articular application. Rest impeller (boss up) up) on a flat surface. Apply grease to the impelle impellerr thread. Place FRAME PLATE LINER INSERT (041) over impeller boss, then screw impeller on shaft. Observe that the various various seals have not shifted and that the spigot on the back of the frame plate liner insert engages fully with the spigot in the frame plate.

(b) 

Fit SHAFT KEY (070) (070) in keyway and bolt bolt SHAFT WRENCH (306) on sh shaft, aft, over key. key. Holding shaft shaft with wrench wrench and turning turning the impeller with a bar between vanes, vanes, nip up impeller on shaft. shaft. Do not over tigh tighten. ten. Check that CLAMP BOLTS (012) on side 'B' of Base (refer to Figure 6) are nipped up just enough to hold the bearing assembly horizontal but not to lock it. To hold the frame plate liner insert temporarily in its correct position, move the bearing assembly back by means of the nut on the ADJUSTING SCREW (001).

(c) 

Fit VOL VOLUTE UTE FRAME FRAME SEAL (125) - {O-ring} {O-ring} over rim of of frame plate liner in insert sert and next to frame plate.

For 4/3 AH Pumps. (a) 

Obtain correct type of IMPELLER (-) as specified for the p particular articular application. Rest impeller (boss up) up) on a flat surface. Apply grease to the impelle impellerr thread. Place FRAME PLATE LINER INSERT (041) over impeller boss, then screw impeller on shaft. Observe that the va various rious seals have not not shifted.

(b) 

Fit SHAFT SHAFT KEY ((070) 070) in keyway keyway and bolt SHAFT WRENCH (306).

FOLLOWING INSTRUCTIONS APPLICABLE FOR PUMPS WITHOUT FRAME PLATE LINER STUDS:

1.

Fit VOLUTE LINER (110) as follows. For two piece metal lined pumps, the volute liner and 'front liner' (throatbush) are one piece. This applies for pump sizes 1.5/1 AH to 4/3 AH pumps. Lift VOLUTE LINER (110) over impeller and push back into frame plate so that the taper of the frame plate liner insert engages with the corresponding taper in the volute liner. liner. Check that that the volute volute frame seal seal (O-ring) (O-ring) had not not shifted. To hold the volute liner temporarily in this position use a G-clamp to clamp the volute liner discharge nozzle nozzle to half flange of of the frame plate. Refer to Figure 6.

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TO PREVENT INJURY IT IS VERY IMPORTANT THAT THE VOLUTE LINER BE HELD FIRMLY DURING THE FINAL STAGES OF ASSEMBLY.

2.

Lift COVER PLATE (013) over volute liner and line up holes with COVER PLATE BOLTS (015) (015) already fitted in frame plate. plate. Screw nuts on cover plate bolts. Do not tighten. Remove G-clamp G-clamp from volute liner then tighten all cove coverr plate bolts evenly to the torque given in Table 1.

3.

Depending on the method used to assemble assemble the gland components, components, complete complete the assembly of gland parts in the stuffing box or expeller ring by following the relevant instructions in Seal Assembly. Assembly. For pumps fitted fitted with Warman mechanical sseals, eals, assembly of the remaining parts and header tank etc should now be completed.

4. 

Pump is now now ready for fitting of joint joint rings and and impeller adjustment. Refer to sections on Assembled Pump - Fitting Joint Rings and Impeller Adjustment respectively.  

5. 

Figure 8

Three Piece Me Metal tal Liners

Metal Liners - Three Piece Piece

Fitting Seal Ring, Volute Liner Seals, Frame Plate Liner Insert, Impeller, Volute Liner, Throatbush and Cover Plate - See Figures 8, 6 and 7 For three piece metal lined pumps, the throatbush is separate to the volute liner. This applies to pump sizes 6/4 AH and larger.

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Page 27 of 48

1.

Fit SEAL RING (122) to stuffing stuffing box or expeller ring. The seal ring is one of two types: 'C' SECTIO SECTION: N:  Pump sizes 6/4 AH & 8/6 AH.

Fit SEAL RING (122) (122) onto rim of stuffing box or or expeller rin ring. g. To aid in holding the seal in position during subsequent assembly steps, it is recommended that the seal be cemented to the stuffing box/expeller ring using rubber cement, and preferably of the dry contact type, with sufficient drying time allowed before contacting the two parts - as per the manufacturers manufacturers instructions. instructions. Furthermore Furthermore,, the cement should only be applied at 4will to ensure 6 'spots'the onseal bottom of unduly the 'C'-section in seal rather than all n. the way around. This sea l is not restrained dur during ing compressio compression. 'O'-RING: Generally pumps above 8/6 AH size.

The seal is an O-ring. Fit into the groove on the rim of the stuffing box or expeller ring. 2.

Fit VOLUTE LINER SEAL (124): The seal is a 'C'-section and it is activated by internal pressure. pressure. Fit it (flat face in) in) into the frame plate groove. groove. Use rubb rubber er contact cement if required.

3.

Fit FRAME PLATE LINER INSERT (041) and IMPELLER (-). Provision is made to accommodate studs or bolts for mounting of the frame plate liner inserts to the frame plate. (a) 

Screw and tighten STUDS (026) in tapped holes provided in frame plate liner insert. Alternatively, depending depending on pump, fit BOLTS BOLTS (040) in 'T'-slots 'T'-slots provided in insert. Screw locknut onto the bolt and tighten tighten so that the BOLTS (040) are held firmly. This will assist assist when fitting fitting the insert so that the bolts w will ill fit through the holes in the frame plate and there will be less chance of dislodging the 'C'-section seals.

(b) 

Suspend LIFTING TUBE (302) from a hoist. (Refer to Figure 7). Stand frame plate liner insert on edge edge and push push lifting tube into insert insert hole. Lift tube with insert and slide tube over shaft shaft thread. Line up studs (or bolts bolts)) with holes and push liner insert insert against frame plate. Check that the var various ious seals had not not shifted. Screw on nuts but do not tighten. Remove lifting tube.

(c) 

Fit SHAFT KEY (070) in keyway and bolt SHAFT WRENCH (306) over key. Check that CLAMP BOLTS (012) on side 'B' of base (refer to Figure 6) are nipped up just enough to hold the bearing assembly horizontal but not to lock it. Hold shaft with wrench and screw LOCATING NUT (303) on shaft - refer to Figure 7. The conical face will will locate the frame plate liner ins insert ert in its correct position. Tighten up all studs, or bolts, on insert insert and then remove locating nut.

(d) 

Check that O-RING O-RING (109 or 064) 064) is correctly seated in groov groove e in expeller or shaft spacer.

(e) 

Obtain ccorrect orrect type of IMPELLER (-) as specified for the particular pump application.

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 Apply grease to thread, lift impeller with a hoist using a rope and screw it onto the shaft. Holding impeller turn turn shaft by means of wrench wrench to screw on impelle impeller. r. Tighten impeller with bar between vanes and flogging shaft wrench.

Ensure that the various O-rings on the shaft are not damaged during assembly and that they are fully covered by the various parts. 4.

For three piece metal lined pumps, the volute liner and 'front liner' (throatbush) are separate pieces. This applies for pump sizes 6/4 AH and larger. (a) 

Using VOLUTE LIFTING BEAM (304) and a hoist to lift VOLUTE LINER (110) off the floor - refer to Figure 7, pass it over the impeller and push back into frame plate so that the taper of the frame plate liner insert engages with the corresponding corresponding taper in the volute volute liner. Check that the vo volute lute frame seal (O-Ring) had not shifted.

(b) 

To hold the volute liner temporarily in this position use a G-clamp to clamp the volute liner discharge nozzle to half flange of the frame plate (refer to Figure 6). TO PREVENT INJURY IT IS VERY IMPORTANT THAT THE VOLUTE LINER BE HELD FIRMLY DURING THE FINAL STAGES OF ASSEMBLY.

(c) 

In large pumps, lugs are provided around the periphery of the volute liner. These lugs are positioned so that some cover plate bolts, with special slots or KEEPER PLATES (081), fit over them - these were the cover plate bolts not fitted to the frame plate in Section on Fitting Frame Plate and Cover Plate Bolts.

Fit these COVER COVER PLATE PLATE BOLTS (015 (015)) now to the frame plate to h old t he volu te liner in positi on during sub sequent a assembly ssembly operations. For bolts with slots ensure the slot in the bolt engages the volute lug before tightening. For bolts with keepe keeperr plates, slide the kee keeper per plate over the cover plate bolt onto the spigot diameter on the centre section of the bolt and push bolt through frame plate such that the keeper plate is closest to the frame plate and bends away from it and engages the lug on the volute liner.

5.

Fit VOLUTE LINER SEAL (a) 

Rest COVER COVER PLATE PLATE (013) (013) {intake {intake flange flange dow down} n} on on suitable supports so as to keep the flange approximately 25 mm above the floor.

(b) 

Fit VOLUTE VOLUTE LINER LINER SEAL (124) {flat face down} in groove groove in cov cover er pl plate. ate.

(c) 

For pumps with THROATBUSH STUDS (026) - {generally 12/10 AH pump and larger} screw studs into tapped holes in the THROATBUSH (083).

(d) 

Lower THROATBUSH (083) into cover plate.

(e) 

For pum pumps ps fitted with cotters cotters {generally {generally 6/4 AH to 10/8 AH siz sizes} es} ins insert ert COTTERS (085) through slots in neck of cover plate and tap them carefully and evenly until the throatbush throatbush is held firm firmly ly in the cover plate. Do Not fully

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tighten at this stage. For pumps fitted with throatbush throatbush studs, screw screw on nuts do not fully tighten at this stage. 6.

Lift COVER PLATE (013) over volute liner and line up holes with COVER PLATE BOLTS (015) already fitted in frame plate. Screw nuts on cover plate bolts. Do not tighten. Remove G-clamp from volute liner then tighten all cover plate bolts evenly to the torque given in Table 1.

7.

Fully tighten all throatbush studs and/or cotters.

8.

Depending on the method used to assemble assemble the gland components, components, complete complete the assembly of gland parts in the stuffing box or expeller ring by following the relevant instructions in section on Seal Assembly. For pumps fitted with Warman Mechanical Seals, assembly of the remaining parts and header tank etc should now be completed.

9. 

Pump is now now ready for fitting of joint joint rings and and impeller adjustment. Refer to sections on Assembled Pump - Fitting Joint Rings and Impeller Adjustment respectively.  

Figure 9 Two Piece Elastomer Liners

Elastomer Liners - Two Piece

Fitting Frame Plate Liner, Impeller, Cover Plate Liner and Cover Plate - See Figure 9

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Following instructions are for series 'A' pumps that have two elastomer liner halves (two piece) consisting consisting of a cover plate liner and a frame frame plate liner. This applies to pump sizes 1.5/1 AH, 2/1.5 AH, 3/2 AH and 4/3 AH. 1.

2.

Fit FRAME PLATE LINER (036) as follows. (a) 

Screw and tighten STUDS (026) in tapped bosses provided in the frame plate liner. Check by eye that the studs are square square with the liner. If not, scr screw ew a nut onto the thread and tap lightly with a hammer to correct.

(b) 

Lift liner liner into position, line up up studs studs with holes holes and push push into fr frame ame plate, fit nuts onto studs and tighten only sufficiently to hold the liner back in the correct position in the frame plate.

Obtain correct type of IMPELLER (-) as specified for the particular pump application. (a)  Rest impeller (boss up) on a flat surface. Apply grease to threads then screw

impeller onto shaft. (b) 

Fit SHAFT KEY (070) in keyway and bolt SHAFT WRENCH (306) onto shaft, over key. Holding shaft with wrench wrench and turni turning ng impeller with ba barr between vanes, nip up impeller on shaft. Do not over tighten. Ensure that the various O-rings on the shaft are not damaged during assembly and that they are fully covered by the various parts.

Fit COVER PLATE LINER (017) and COVER PLATE (013) as follows. (c) 

Screw and tighten tighten STUDS STUDS (023) (023) in tapped bosses (3/2 AH and 4 4/3 /3 AH pumps), on COVER PLATE LINER (017). Check for squareness and correct if necessary.

(d) 

Place cover plate liner on the floor (intake flange up). Apply a liberal amount of liquid soap or rubber lubricant on the intake flange and inside the intake neck of COVER PLATE (013).

(e) 

Place ccover over plate plate over cover plate liner, liner, line up stud studss with holes (when (when provided), and press cover plate down until liner is hard against cover plate. Insert a small tire iron between intake neck and liner an and d lift flange out. Fit nuts onto studs and tighten.

(f) 

Lift cover cover plate complete with liner and line up h holes oles with COVER PLATE BOLTS (015) already in the frame plate. Screw nuts on cover plate bolts and tighten evenly to torque given in Table 1.

3.

Depending on the method used to assemble assemble the gland components, components, complete complete the assembly of gland parts in the stuffing box or expeller ring by following the relevant instructions in Section Seal Assembly. For pumps fitted with Warman mechanical seals, assembly of the remaining parts and header tank etc should now be completed.

4. 

Pump is now now ready for fitting of joint joint rings and and impeller adjustment. Refer to sections on Assembled Pump - Fitting Joint Rings and Impeller Adjustment respectively.  

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Page 31 of 48

Figure 10

Three Piece Elastomer Liners

Elastom er Liners - Three Piece

Fitting Frame Plate Liner, Impeller, I mpeller, Throatbush, Cover Plate Liner and Cover Plate - See Figures 10, 6 and 7 Following instructions are for series 'A' pumps that have three piece elastomer liners consisting of a frame plate liner, liner, cover plate liner and throa throatbush. tbush. This applies to pump si zes 6/4 AH, 8/6 AH, 10/8 AH, 12/10 AH and 10/8 M. M.

1.

2.

Fit FRAME PLATE LINER (036) as follows. (a) 

Screw and tighten tighten STUDS STUDS (026) (026) in tapped bosses provided in the frame p plate late liner.

(b) 

Lift liner into position, position, line up studs studs with holes and and pus push h into frame p plate, late, fit nuts onto studs and tighten only sufficiently to hold the liner back in the correct position in the frame plate.

(c) 

Hold shaft with wrench and screw on LOCATING NUT (303) on shaft. The conical face will locate the frame plate liner insert in its correct position. Tighten up all studs and remove locating nut.

Fitting IMPELLER (-): Proceed as follows.

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(a) 

Fit SHAFT KEY (070) (070) in keyway and bolt bolt SHAFT WRENCH (306) over key. Check that CLAMP BOLTS (012) on side 'B' of base are nipped just enough to hold the bearing assembly horizontal horizontal but not to lock it.

(b) 

Obtain correct correct type of IMPELLER (-) as specified for the particular pump application.  Apply grease to thread, lift impeller with a hoist using a rope and screw it onto the shaft. Holding shaft with wrench and turning impeller with bar between vanes to tighten impeller on shaft. shaft. Ensure that the various various O-rings O-rings on the shaft are not damaged during assembly and that they are fully covered by the various parts.

3.

Fit COVER PLATE LINER (018) and THROATBUSH (083) as follows. FOR 6/4 6/4 AH, 8/6 AH, 10/8 AH and 10/8 M Pump Pump s

For these pumps the LINER SEAL (124) is integral with the COVER PLATE LINER (018). Proceed as follows. (a) 

Place COVER COVER PLATE PLATE LINER (018) {flange {flange down} down} on floor with with a block in the centre of sufficient height to finish flush or slightly above the liner and rest on it the THROATBUSH (083) {intake flange up}.

(b) 

Apply a liberal amount of liquid soap or rubber rubber lu lubricant bricant on tape tapered red ed edge ge of throatbush and on lip seal of liner.

(c) 

Lift and tilt liner to engage engage lip seal seal over over one one thir third d of the thr throatbush oatbush diameter.

Run a small tire iron with rounded edges between throatbush and liner and lift lip seal to engage over the back of the throatbush. Ensure that the lip is properly set. Care must be taken during this operation not to damage or tear the lip seal.

Continue instructions at 3 (e) below. (d) 

For 10/8 AH pum p  fit STUDS (026) in tapped bosses in throatbush.

FOLLOWING INSTRUCTIONS APPLICABLE TO 6/4 AH, 8/6 AH, 10/8 AH, 12/10  AH & 10/8 M PUMPS:  (a) 

Lift COVER PLATE (013) (013) {intake {intake flange flange up} and fit over the throa throatbush tbush a and nd liner.

(b) 

For 6/4 AH, 8/6 AH and 10/8 M pumps : Insert COTTERS (085) through slots

in neck of cover plate and tap them carefully and evenly until throatbush is held firmly in cover plate. (c) 

For 10/8 AH pum p : Fit nuts to studs and tighten.

FOR 12/10 12/10 AH Pump

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

(a)

Rest COVER PLATE (013) {intake flange down} on suitable supports so as to keep flange approximately 25 mm above the floor. f loor.

(b)

Fit VOLUTE VOLUTE LINER LINER SEAL (124) {flat face down} in the groove in ccover over plate.

(c)

Fit THROATBUSH THROATBUSH STUDS (026) to THROATBUSH THROATBUSH (083), line up studs studs with holes in cover plate and lower throatbush in position, screw nuts on studs and loosely tighten.

(d)

Screw COVER PLATE LINER LINER STUDS STUDS (023) (023) in COVER PLATE LINER LINER ((018) 018) tapped bosses, fit Liner in cover plate and ensure that studs line up with respective holes in cover plate, screw nuts on studs and tighten.

(e)

Tighten THROATBUSH STUDS (026).

Fit COVER PLATE (013). Lift cover plate complete with throatbush and cover plate liner and line up holes with COVER PLATE BOLTS (015) already in frame plate. Note: Large cover plates are provided provided with radially radially tapped holes for eye bolts to facilitate lifting. Screw nuts on cover plate bolts and torque evenly to the value given in Table 1.

2.

Depending on the method used to assemble assemble the gland components, components, complete complete the assembly of gland parts in the stuffing box or expeller ring by following the relevant instructions in Section on Seal Assembly. For pumps fitted with Warman mechanical seals, assembly of the remaining parts and header tank etc should now be completed.

3.

Pump is now ready for fitting of joint joint rings rings and impeller adjustment. Refer to sections on Assembled Pump - Fitting Joint Rings and Impeller Adjustment respectively.

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Figure 11

Elastomer Liners - Four Piece

Fitting Liner Seals, Frame Plate Liner Insert, Frame Plate Liner, Impeller, Throatbush, Cover Plate Liner and Cover Plate - See Figures 11, 6 and 7 Following instructions are for Series 'A' pumps that have four piece elastomer liners consisting of Frame plate liner insert, frame plate liner, cover plate liner and throatbush. 16/14 4 AH, 20/18 AH and 12/10 M. This applies to pu mp si zes 14/12 AH, 16/1 1.

Fit VOLUTE LINER (124), FRAME PLATE LINER INSERT (041) and FRAME PLATE LINER (043)SEAL as follows. For p um umps ps 14/1 14/12 2 AH, 16/1 16/14 4 AH and 20/18 AH (a) 

Fit VOLUTE VOLUTE LINER LINER SEAL (124) {flat face face in} into fr frame ame pla plate te groov groove. e. Us Use e

rubber cement preferably to hold in position. (b) 

Screw and tighten FRAME FRAME PLATE PLATE LINER INSERT STUDS (026) in ta tapped pped bosses provided in the FRAME PLATE LINER INSERT I NSERT (041).

(c) 

Suspend LIFTING TUBE (302) from a hoist {refer to Figure 7}. Stand frame plate liner insert on edge edge and push tube into insert insert hole. Lift tube with insert and slide tube over over shaft thread. thread. Line up studs w with ith holes and p push ush liner insert against against frame plate. Screw on nuts but do not tighten tighten.. Remove lifting tube.

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(d) 

Screw and tighten FRAME PLATE PLATE LINER LINER STUDS STUDS (023) (023) iin n tappe tapped d bos bosses ses in FRAME PLATE LINER (043).

(e) 

Lift frame plate liner liner in position by means means of a hoist and line up stu studs ds with holes in frame plate, plate, push liner against against frame plate. Screw on nuts nuts..

For 12/10 M Pum Pump p

2.

(a) 

Lift FRAME PLATE LINER LINER (043) (043) by means of hois hoistt and fit to frame plate. Smear liquid soap or rubber lubricant onto spigot step in frame plate liner where frame plate liner insert will fit.

(b) 

Screw and tighten FRAME FRAME PLATE PLATE LINER INSERT STUDS (026) in ta tapped pped bosses in FRAME FRAME PLATE LINER INSERT INSERT (041). Lift frame plate liliner ner insert into position by means of a hoist and line up studs with holes in frame plate, push insert against against frame plate liner. liner. Screw on nuts.

Fitting IMPELLER (-): Proceed as follows. (a) 

Fit SHAFT (070) in keyway bolt 'B' SHAFT WRENCH (306) over6, key. Check that KEY CLAMP BOLTS (012) and on side of base - refer to Figure are nipped just enough to hold the bearing assembly horizontal horizontal but not to lock it.

(b) 

Hold shaft with wrench and screw on LOCATING NUT (303) on shaft. The conical face will locate the frame plate liner insert in its correct position. Tighten up all studs, {frame plate liner insert studs and/or frame plate liner studs} and remove locating nut.

(c) 

Obtain ccorrect orrect type of IMPELLER (-) as specified for the particular pump application.  Apply grease to thread, lift impeller with a hoist using a rope and screw it onto the shaft. Holding impeller turn turn shaft by means of wrench wrench to screw on impelle impeller. r. Tighten impeller with bar between vanes and flogging shaft wrench. Ensure that the various O-rings on the shaft are not damaged during assembly and that they are fully covered by the various parts.

3.

Fit COVER PLATE LINER (018) and THROATBUSH (083) and COVER PLATE (018) as follows. FOR 14/12 AH, 16/14 AH and 20/18 AH PUMPS (a) 

Rest COVER COVER PLATE PLATE (013) (013) {intake {intake flange flange dow down} n} on suitable supports so as to keep flange approximately 25 mm above the floor. f loor.

(b) 

Fit LINER LINER SEAL (124) {flat face face down} in the groove in cover cover plate.

(c) 

Fit THR THROATBUSH OATBUSH STUDS (026) to THROATBUSH THROATBUSH (083), line up studs with holes in cover plate and lower throatbush in position, screw nuts on studs.

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(d) 

Screw STUDS (023) in COVER COVER PLATE LINER (018) tapped bosses, fit liner in cover plate and ensure that studs line up with respective holes in cover plate, screw nuts on studs and tighten. Tighten THROATBUSH STUDS (026).

FOR 12/10 M PUMP

(a)

Rest COVER PLATE (013) {intake flange down} on suitable supports so as to keep flange approximately 25 mm above floor. Fit COVER PLATE LINER (018) to cover plate and smear liquid soap or rubber lubricant onto spigot step in cover plate liner where throatbush will fit.

4.

(b)

Lower THROATBUSH (083) into cover cover plate plate and push fifirmly rmly down down to rest o on n cover plate liner.

(c)

Insert COTTERS COTTERS (085) (085) through through slots in neck of cover plate and tap them carefully and evenly until the throatbush is held firmly in the cover plate.

Fit COVER PLATE (013). Lift cover plate complete with throatbush and cover plate liner and line up holes with COVER PLATE BOLTS (015) already in frame plate. Note: Large cove coverr plates are provided provided with radially tapped tapped holes for eye bolts bolts to

facilitate lifting. Check all liner stud nuts and throatbush cotters for tightness.

Screw nuts on cover plate bolts and torque evenly to the value given in Table 1. 5.

Depending on the method used to assemble assemble the gland components, components, complete complete the assembly of gland parts in the stuffing box or expeller ring by following the relevant instructions in section on Seal Assembly.

6.

For pumps fitted with Warman Mechanical Seals, assembly of the remaining parts and header tank etc should now be completed.

7. 

Pump is on nowAssembled now ready for fitting joi nt rings and andRings impeller Refer to sections Pump of- joint Fitting Joint andadjustment. Impeller Adjustment respectively.  

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Figure 12

 As sem sembl bl ed Pu mp : Fit ti ng Jo in t Ri ng s - See Figu Fi gu re 12

1.

The Pump is now fully assembled. For pumps requiring INTAKE JOINT RING (060) and DISCHARGE JOINT RING (132), they are supplied loose. Fit the INTAKE JOINT RING (060) and the DISCHARGE JOINT RING (132) as shown in Figure 12. Use rubber cement cement to hold joints in position while connecting connecting intake and discharge pipe work. Impeller clearance has now to be adjusted refer to Impeller Adjustment.

2. 

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Install pipe from drip tray in BASE (003) {when fitted} to remove gland leakage leakage.. 

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Figure 13

Impeller Ad jus tment - See Figures 13 & 6

In both METAL and RUBBER LINED PUMPS the impeller should just clear the front liner (throatbush).. This is particularly (throatbush) particularly important important for high efficiency efficiency impellers impellers without front front vanes (type HE and HN).  1.

Rotate shaft clockwise by hand and move bearing assembly forward (towards front liner) by tightening the rear nut on the ADJUSTING SCREW (001) until the impeller starts to rub on the front liner.

2.

Release the rear rear nut by one one sixth sixth of of a turn, then m move ove bearing assembly back by means of front nut until housing touches the rear lug. NOTE

Impeller adjustment adjustment is a key key element in extending the wear wear life. Field tests on certain pumps indicate if impellers are adjusted right forward when fitted and again at regular over intervals during thewere wearnot life, then anadjusted increaseforward of 40–50% in initial life can be achieved pumps which correctly at the fit-up. Further, pumps which were regularly adjusted over their life have shown a 20% increase over pumps which were only adjusted once at the initial fit up. Recommended procedure: (a)

On initial fit-up, adjust the impeller impeller so it "jus "justt touches" touches" the throatbush. 

(b)

Re-adjust the impeller to "just "just touch" touch" the throatbush after 50–100 hours.

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(c)

Re-adjust a further two to three times times at regular intervals during the wea wearr life of the pump (this could coincide with the regular maintenance times – say 500 hours).

(d)   After adjustment of the impeller, it is important to tighten the bearing housing clamp bolt to a torque value given in the following Table. 

BEARING HOUSING CLA CLAMP MP BOLT TORQUE TAB TABLE LE FRAME SIZE

MAXIMUM TORQUE (Nm)

 A

10

B

FRAME SIZE

MAXIMUM TORQUE (Nm)

10

N, NP

25

C, CC

45

P, PQ

45

D, DD

45

Q, QR

45

E, EE

185

R, RS

185

F, FF

185

S, ST

185

G, GG

325

T, TU

525

H

1500

U, UV

1500

THE PUMP IS NOW COMPLETE AND READY FOR ASSEMBLY OF DRIVE COMPONENTS  AND INSTA LL ATION. PACKING WILL REQUIRE REQUIRE FINAL A DJUSTMENT DURING DURING INITIAL INITIAL START-UP

3

PUMP DISM DISMANTLING ANTLING & IMPELLER REMO REMOVAL VAL Dismantling the pump is the reverse of the instructions given for assembly purposes with the exception of removing the impeller on the larger pumps. To gain access (083) to the can IMPELLER (-) generally the pump cover by plate complete or THROATBUSH be withdrawn from the removing thewith nutsliners on the COVER PLATE BOLTS (015) and for metal lined pumps the metal VOLUTE LINER (110).  All Warman pumps utilise a threaded threaded shaft and impeller. impeller. To assist in removing impel impellers lers on large pumps pumps they are fitted with an IMPELLER RELEASE COLLAR (239). The impeller release collar is first removed which allows the impeller to be unscrewed easily from the shaft. Full instructions relating to IMPELLER RELEASE COLLARS (239) are given in Warman Supplement 'M2'.

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PRODUCT MODIFICATION ADVICE (PMA) This manual has been compiled from the latest information and revisions regarding Warman TYPE 'AH' pump fit-up. Over time improvements improvement s have been incorporate incorporated d into certain pumps and advice distributed in the form of Product Modification Advice (PMA)

certain pumps and advice distributed in the form of Product Modification Advice (PMA) sheets. Listed below are the relevant relevant PMA's for TYPE 'AH' pumps. If further information information is required on any of these topics please contact your nearest Weir Warman Office.

PMA No

ISSUED DATE

DESCRIPTION

PMA -110-1

Aug 76

Modification to existing 12/10 AH Cover Plates for fitting redesigned moulded liners

PMA-110-3

Mar 77

Correction to Frame Plate Liner Part Numbers.

PMA-110-4

Aug 78

Conversion of FAM Frame pumps Shaft  Assembly with Release Collar Collar

PMA-110-9

May 80

16/14 G-AH modification of Gland & Centrifugal Seal.

PMA-110-11

May 80

D-AH pumps: Modification of Centrifugal Seal

PMA-110-12

Dec 80

Provision of holding the Volute Liner in position during Assembly - pump 6/4 AH, 8/6 AH, 10/8 M and 12/10 M

PMA-110-13

Jan 81

List of interchangeable interchange able Imperial and Metric Parts.

PMA-110-15

Jun 82

Change of Designatio Designations ns of some Series 'A' Pumps.

PMA-110-18

Oct 82

12/10 AH pump: Modification of method of retaining Throatbush

PMA-100-19

Mar 83

Securing the Frame Plate Liner Insert Bolt to the Liner Insert.

PMA-110-20

Sep 83

16/14 AH Pump: Modification of method of retaining Throatbush.

PMA-110-26

Mar 85

Discharge Joint Rings (132)

PMA-110-27

May 85

Frame Plate Liner Inserts: Change from Bolts to Studs.

PMA-110-28

Sep 85

Improved method of fixing F4041

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PMA No

ISSUED DATE

DESCRIPTION

PMA-110-29

Sep 85

Improved method of fixing F8041

PMA-110-30

Sep 85

Improved method of fixing F10041

PMA-110-31

Jan 86

Bearing Assembly END COVERS (024)

PMA-110-38

Oct 87

Split type Lantern Ring

PMA-110-39

Aug 87

Expeller EAM028

PMA-110-40

Apr 88

Frame Plate Liner Insert Studs

PMA-110-41

Sep 88

Expeller CAM028 & 'O'-ring D064

PMA-110-48

Dec 89

Bearing Assembly

PMA-110-53

May 93

Rubber Impeller with metal boss cap

PMA-110-59

Aug 91

10/8 AH Method of retaining throatbush

PMA-110-61

Sep 91

6/4 D-AH & 6/4 E-AH Bearing Assembly

PMA-110-63

Jan 92

Bolts & Tee slots for fixing Volute

PMA-110-64

Apr 92

8/6 F-AH modified impeller MK119402C

PMA-110-65

Jun 92

Modification Modificat ion on the reduced eye impellers

PMA-110-66

Jun 92

Change Liner Part No.

PMA-110-69

Aug 92

Change high efficiency impeller & throatbush Part No.

PMA-110-70

Aug 92

10/8M impeller F8145HE2 Part No was MK124934A

PMA-110-84

Oct 92

Change Volutes Part No

PMA-110-86

Nov 92

Change impeller Part No

PMA-110-87

Nov 92

Change 16/14 G-AH impeller Part No

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BASIC BA SIC PART NU NUMBERS MBERS & PARTS LIST L IST

FRAME PLATE LINER INSERT (041) 27, 28, 30, 37, 38 FRAME PLATE LINER INSERT STUDS (026)   37, 38

 A  

FRAME PLATE LINER STUDS (023)   ADJUSTING SCREW (001) 

8, 28, 41

FRAME PLATE STUDS (039) 

B 

38 9

G 

BASE (003) 

8, 40

GLAND (044) 

14, 15, 21, 22

BEARING ASSEMBLY (005) 

8, 24

GLAND BOLTS (045) 

14, 15, 21, 22

GLAND CLAMP BOLTS (126) 

14, 15, 21, 22

BOLTS (040) 

30

GREASE CUP (-)  GREASE CUP ADAPTOR (138)  

C  CLAMP BOLTS (012) 

8, 27, 30, 35, 38

21, 22 21, 22

I  CLAMP BRACKET (022) 

15

CLAMP BRACKET SET SCREW 

15

CLAMP WASHER (011) 

8

COTTERS (085) 

IMPELLER (-) 

IMPELLER RELEASE COLLAR (239)14, 15, 21, 22, 23,

31, 35, 39

COVER PLATE (013) 

28, 31, 33, 35, 36, 39

COVER PLATE (018) 

38

15, 27, 28, 30, 33, 34, 35, 38, 42

42, 43

INTAKE JOINT RING (060) 

COVER PLATE BOLTS (015)  10, 28, 31, 33, 36, 39, 42 COVER PLATE LINER (017)

40

K 

33

COVER PLATE LINER (018)  

35, 36, 38, 39

COVER PLATE LINER STUDS (023) 

KEEPER PLATES (081)  

10, 31

36

L 

D  LABYRINTH (062)  DISCHARGE JOINT RING (132) 

40

8, 11, 14, 15, 17, 21, 23

LANTERN RESTRICTOR (118) 

14, 15

LANTERN RESTRICTORS (118-1) 

11

LANTERN RING (063) 

E 

14, 15, 20, 22

LANTERN RING (063R)  END COVER (024) 

24

LIFTING PLATE (310) 

14, 21

END COVER (024-50) 

24

LIFTING TUBE (302) 

30, 37

LINER SEAL (124) 

35, 39

EXPELLER (028) 

18, 21, 22, 24

EXPELLER RING (029) 

20, 22

LIP SEAL GLAND (241)  

23 23

EXPELLER RING (029R) 

23

LIP SEALS (090) 

EXPELLER RING LIFTING BEAM (310) 

22

LOCATING NUT (303) 

EXPELLER RING STUDS (079)  

23

EYE BOLTS (-) 

9

FRAME PLATE (032) 

9

FRAME PLATE BOLTS (034)  

9

FRAME PLATE LINER (036) 

32, 34

FRAME PLATE LINER (043) 

37, 38

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30, 34, 38

N  NECK RING (067) 

F 

 

23

14, 15, 20, 22

O  O-RING (109 or 064) 

21, 22, 24, 30

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STUDS (026) 

P 

30, 33, 34, 35

STUFFING BOX (078)   PACKING (111) 

20

PACKING RING (111) 

13, 15

STUFFING BOX LIFTING PLATE (310) 

15

14, 15, 20, 22

T  S  THROATBUSH (083)  SEAL RING (122)   SHAFT (073)  SHAFT KEY (070)  SHAFT SLEEVE (075 or 076)  

27, 29

THROATBUSH STUDS (026) 

V 

27, 28, 30, 33, 34, 38 14 20, 21, 22, 23, 24

SHAFT SPACER (117) 

18 27, 28, 30, 33, 34, 38

VOLUTE FRAME SEAL (125)   VOLUTE LIFTING BEAM (304)  VOLUTE LINER (110)  VOLUTE LINER SEAL (124 or 125) 

STUDS (023) 

31, 36, 39

8

SHAFT SLEEVE (075)  SHAFT WRENCH (306) 

31, 35, 36, 38, 39, 42

33, 39

VOLUTE LINER SEAL (124)  

27, 28 31 10, 28, 31, 42 27 27, 30, 31, 36, 37

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

 APPENDIX Fitting Ela Elastomer stomer Cover Plate Liner and Throatbush

These instructions apply to pumps which have an integral volute seal as part of the cover plate liner. This applies to the the following pumps: pumps: 10/8 AH, 10/8 M and 8/6 8/6 AH. While there are a number of different methods available, the following method eases assembly particularly if super thick elastomer liners are being fitted or studs are utilised to hold the throatbush into the cover plate (ie no cotters).

Figure 1

1.

For pumps with throatbush studs only.

Fit the cover plate liner to the cover plate and mark a line on the outside of the liner so that the throatbush studs will line up on final assembly with the holes in the cover plate. 2.

Support the cover plate liner, seal side up with blocks of timber.

3.

Lubricate outside of throatbush and cover plate seal with rubber lubricant or similar.

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Figure 2

4.

Lift throatbush throatbush on top of liner liner and and push push one one side side of the thr throatbush oatbush underneath the sseal eal lilip. p.

5.

Use levers to lift the seal working around the edge of the throatbush. Levers plus pressure pressur e on top of the throatbush will allow the throatbush to slip into place on the taper.

Figure 3

6.

Rotate throatbush if required to align marks for stud near the cutwater.

Figure 4

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Figure 5

7.

Lower cover plate over liner and throatbush till throatbush throatbush studs protrude through holes.

8. 9.

Push down on cover plate if required. Fit nuts to the throatbush studs and tighten.

Figure 6

10.

Lift cover plate vertically vertically and knock liner into cover plate plate with a rubber mallet if re required. quired.

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| P03 Series 'A' Slurry Pumps (AH & M) Jan 07.doc 

Figure 7

11.

Check throatbush studs are tight tight and and liner liner fit is correct. correct.

Figure 8

12.

Fit cover cover plate with liner liner to pump in normal manner manner using using ccover over plate bol bolts. ts.

Complete assembly procedures.

Page 47 of 48

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© Copyright Weir Minerals Australia Ltd

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 A s s emb  As em b l y & Main Mai n t enan en anc ce Instructions Sup uppl ple ement ‘M8 ‘M8’’ Warm Wa rman an High Se Seal al Cent Centri rifu fugal gal Sea Seall Type Typ e ‘HS’ ‘HS’

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

Office of origin : Date :

 

Pump Technology Centre, Artarmon 23 January 2007

Reference : Last Issued:

Pump Manuals July 2005

 

Weir Minerals

| M08 High Seal Centrifugal Seal (HS) Jan 07.doc  

Warnings Personnel injury and / or equipment damage could result from not observing the following IMPORTANT SAFETY INFORMATION. •   A 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, mechanical seals, etc) all related safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment   and maintenance. •   All guards  for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards should not be removed or opened while the pump is running. Personal injury may result from contact with rotating parts, seal leakage or spray. •  Driver rotation must b e checked checked  before belts or couplings are connected. •  Pumps must not be operated 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 high temperature and pressure created. •  Pumps must be used only within their allowable limits  of pressure, temperature and speed. These limits are dependent on the pump type, configuration and materials used. •  Do not apply heat heat to t he 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. •  LIFTING of components • 

Tapped holes (for eye bolts) and lugs (for lifting shackles) on Warman pumps are for

• 

lifting only. only Lifting Individual devices devices of parts adequate adequa te .capacity capacity must be used used wherever wherever they are are required to be

used. •  Safe workshop practices should be applied during all assembly and maintenance work. •  Personnel must never work under suspended loads. •  The pump must be fully isolated   before any maintenance work, 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. • 

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Castings   made from materials listed are brittle and have low thermal shock resistance.

 Attempts to repair or rebuild by welding may cause catastrophic catastrophic failure. Repairs of such castings using these methods must not be attempted - A03, A04, A05, A06, A07, A08, A09,  A12, A14, A49, A51, A52, A53, A53, A61, A210, A211, A217, A217, A218, A509. •  Impellers  must be tight t ight on the shaft before any start-up, ie all components on the shaft between the impeller and the pump end bearing must butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking etc. •

  Burning  of elastomer pump components will cause emission of toxic fumes and result in air pollution which could lead to personnel injury. • 

Leakage from the pump shaft seals and/or leakage from worn pump components or seals may

cause water and/or soil contamination. contamination. • 

Liquid waste disposal  from servicing of pumps or stagnant water from pumps stored for long

periods, may cause water and/or soil contamination. •  Do not apply anti-seize compounds   to the impeller or shaft threads or to elastomer seals during assembly. Anti-seize can greatly reduce the impeller thread friction and may cause the impeller to loosen during pump shut-down and run-back resulting in pump damage, or the elastomer seals to leak at reduced pressure. •  This manual applies only to genuine Warman parts  and Warman recommended parts. •  Mixing of new and worn pump parts  may increase the incidence of premature pump wear and leakage. •  Large foreign objects or tramp  entering a pump will increase the incidence of higher wear and / or damage to the pump. Routine inspection and maintenance of mill trommel screens will assist to reduce the danger of grinding balls entering a mill discharge pump. •  Large variations in slurry properties may lead to accelerated rates of wear and corrosion of pump components eg •  Wear increases exponentially exponentia lly with velocity and slurry particle size. •  Corrosion rate doubles for every 10 degree Celsius increase in slurry temperature. temperature . •  Corrosion rate increases exponentially exponentiall y as slurry pH decreases.

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ISSUED: JA NUARY 2007

LA ST ISSUE: JULY 2005

WARMAN PUMPS

 ASSEMBLY AND MAINTENANCE MAINTENANCE INSTRU INSTRUCTIONS CTIONS SUPPLEMENT SUPPLEME NT ‘M8’ ‘ M8’

WARMAN HIGH SEAL CENTRIFUGAL SEAL TYPE ‘HS’

CONTENTS WARNINGS

2 

CONTENTS

4 

1. 

INTRODUCTION

5 

2. 

 ASSEMBL Y

5 

3. 

Fig 1 & A3-110-0-128677

5 

Frames C, D, E & F

5 

Frame G

7 

8 

 APPLICATION  APPL ICATION  Ap pl icati ic ati on wi th Stan dard dar d Im pel peller ler s

8

 Ap pl icati ic ati on wi th High Eff Effic ic ien cy Imp ell ellers ers (impel (im peller ler s w it itho ho ut back bac k v anes) anes )

9

Impeller adjustm ent

 APPENDIX 1

12 

BASIC BA SIC NUMBERS NUMBERS AND PARTS LIST

14 

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10

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1.

| M08 High Seal Centrifugal Seal (HS) Jan 07.doc  

INTRODUCTION The following instructions instructions apply apply to the Warman type type 'HS' centrifugal centrifugal seal. Refer to the typical 10/8 F-AH Components Diagram Drawing A3-110-0-128677 attached for identification of correct part numbers and their location.

Note that most part numbers incorporate a three digit Basic Part Number (e.g. expellers have the Basic Part Part Number 028). The product code code (HS1) attached to the Basic Basic Part Number indicates indicates the part is specific to a type 'HS' ce centrifugal ntrifugal seal arrangement. arrangement. Basic part numbers as well as the product codes are used in the following instructions.

2.

ASSEMBLY Fig 1 & A3-110-0-128677  In general the Hi-Seal Expeller (028HS1), Expeller Ring (029HS1) and Frame Plate Liner Insert (041HS1) substitute directly for the corresponding standard parts (028, 029 and 041). The 'HS' Expeller replaces the standard standard Expeller or Shaft Spacer (117) in the gland sealed arrangement. arrangement. Often a different Lantern Ring (063HS1) (063HS1) is required. required. For further details of the Hi Seal Expeller Seals and Hi Seal Expeller Conversion Kit, please refer to the Table 1. Date

Descrip tio n  

PMA or NPA

Jul 94

PMA 110-099/1

Lip Seals

Jul 96

PMA 110-103/3

Type HS - Hi Seal Expeller Seals

 Ap r 95

PMA 110-107

Lip Seals

May 95

PMA 110-108

1.5/1B-AH & 2/1.5B-AH High Seal Expellers

 Ap r 96

NPA 110-030/1

Hi Seal Expeller Conversion Conversion Kit Part Numbers

Table 1: 1: PMA and NPA referen ce

The assembly of the type 'HS' centrifugal seal follows precisely the same procedures as the standard Warman centrifugal seal with the modified Hi-Seal parts simply replacing the corresponding correspon ding standard components. components. The following instructions instructions assume that the Bearin Bearing g  Assembly is fitted to the Base Base and the appropriate appropriate Frame Frame Plate is attached to the Base. Different methods are described below for assembling the type 'HS' centrifugal seal, depending on the pump frame. frame. Either method can be used dep depending ending upon suitability. suitability.

Frames C, D, E & F 1.

Place EXPELLER RING (029HS1) flat on bench (gland side up).

2.

Stand SHAFT SLEEVE (075) on end through expeller ring.

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| M08 High Seal Centrifugal Seal (HS) Jan 07.doc  

Fit the following items in turn: (a)

First PACKING RING (111) of correct length to fill an annulus. nulus.

(b)

LANTERN RING (063 [HS1]) pressed down to flatten first ring.

Remaining Packing Ring(s) stagger Packing joints and flatten each Ring to almost completely fill the annulus. 4.

Assemble GLAND (044[HS1]) halves, insert GLAND CLAMP BOLTS (126) and fully tighten. Place Gland in Expeller Expeller Ring and push push down to compress compress Packing R Rings. ings. Insert GLAND BOLTS (045) and just nip up Nuts sufficiently to hold Shaft Sleeve (final adjustment will be made when commissioning commissioning the pump).

5.

From a components diagram (for the particular pump being assembled) ascertain the components which fit between the LABYRINTH (062) and SHAFT SLEEVE (075). Fit these these components components to the Shaft. Instructions for fitting an IMPE IMPELLER LLER RELEASE COLLAR (239) are contained in Warman Supplement ‘M2'.

6.

Insert assembled type 'HS' Expeller Ring in Frame Plate and tap in position with a mallet. Locate Expeller Expeller Ring Ring with grease or flushin flushing g inlet at the top. The Shaft Sleeve will probably probably remain forward. It should be pushed back back to the mating part on the Shaft. Check that that any O-Rings O-Rings are correctly correctly positioned in grooves. All O-Rings should be free of nicks or tears. Note:

The frame plate liner insert studs will hold the expeller ring in position once the frame plate liner insert is installed.

7.

Position O-Ring which the SHAFT SLEEVE (075)sleeve. and EXPELLER (028HS1)the onto the shaft andfits fit between to the groove in the end of the shaft

8.

Place the type 'HS' EXPELLER (028HS1) on Shaft and press up to ma mating ting part part o on n Shaft.

9.

Fit the volute liner seal and expeller ring 0-ring into position. The frame plate liner insert or the frame plate liner can now be located and the frame plate liner insert studs tightened to hold the expeller ring in place.

10.

Fit remaining O-Ring (109 or 064) to groove on Expeller.

Note:

(a)

To assist assist in holding holding the last O-Ring O-Ring in position which which seals against the Impeller, apply heavy grease to the O-Ring groove.

(b)

All the O-Rings in their respective grooves will be compressed and fully covered by these metallic parts when the impeller is screwed onto the Shaft.

11.

Liberally grease Shaft thread. Do not use excessive grease as this could prevent the impeller screwing on fully.

12.

Assembly of the gland gland lubricating lubricating parts will be done done after all other parts of the pump have been assembled. Fit GREASE CUP ADAPTOR (138) and GREASE CUP (-)

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to Expeller Ring. Ring. Fill Cup with recommended recommended grease and screw down Cup to charge Lantern Lantern Ring. Ring. Top up Cup. Cup. Alternatively, connect the flushing w water ater supply to the expeller ring. 13.

Assembly of the rest of the parts follows normal practice. Refer to the relevant Warman maintenance supplement.

Frame G 1.

From a components components diagram ascertain the components components which fit on the shaft between the LABYRINTH (062) (062) and type ‘HS’ EXPELLER (028HS1). (028HS1). Fit these components to the Shaft. Instructions for fitting an IMPELLER RELEASE RELEASE COLLAR (239) are contained in Warman Supplement ‘M2'.

2.

Fit LANTERN RING (063HS1) freely over the Shaft Shaft S Sleeve leeve and push against the Bearing Housing.

3.

Attach the EXPELLER RING LIFTING BEAM (310) to the type 'HS' EXPELLER RING (029HS1) on opposite side of lugs using three jacking screws provided and ensure that the grease inlet in the Expeller Ring is in line with the Lifting Beam.

4.

Lift Expeller Expeller Ring with Lifting Beam by means of a hoist and insert Expeller Ring in Frame Plate, tap in position with with mallet. Grease location location recess to assist late laterr removal. Note:  

The frame plate liner insert studs will hold the expeller in position once the frame plate liner insert is installed. 5.

Assembly of all gland parts parts in type type 'HS' 'HS' Expeller Expeller R Ring ing will be carried out iin n the following manner after all other parts of the pump have been assembled.

6.

(a)

Fit first PACKING RING RING (111) (111) of correct length to fill annulu annuluss and push against bottom lip of the Expeller E xpeller Ring.

(b)

Slide LANTERN RING (063HS1) and press to flatten first Ring.

(c)

Fit remaining remaining Packing Packing Ring(s) Ring(s) to almost almost completely completely fill the annulus annulus -s -stagger tagger Packing joints and flatten each Ring.

(d)

Assemble GLAND (044) halves over Shaft Sleeve with Gland spigot towards Expeller Ring, insert insert GLAND CLAMP CLAMP BOLTS (126) a and nd fully tighten. Push into Expeller Ring to compress compress Packing Packing Rings. Insert GLAND BOLTS BOLTS (045) and nip up. (Final adjustment will be made when commission commissioning ing the pump).

(e)

Fit GREASE GREASE CUP ADAPTOR (138) and GREASE CUP (-) to Expeller Expeller R Ring. ing. Fill Cup with recommended grease and screw down Cup to charge Lantern Ring. Top up Cup. Cup. Alternatively, connect the flus flushing hing w water ater ssupply upply to the expeller ring.

Position the O-Ring O-Ring which fits between between the SHAFT SHAFT SLEEVE (075) and type 'HS' EXPELLER (028HS1) onto the shaft and fit to the groove in the end of the shaft sleeve.

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7.

Place the type 'HS' EXPELLER (028HS1) on Shaft and press up to ma mating ting part part o on n Shaft.

8.

Fit the volute liner seal and expeller 0-ring into position. The frame plate liner insert or the frame plate liner can now be located and the frame plate liner insert studs tightened to hold the expeller ring in place.

9.

Fit remaining O-RING (109 or 064) to groove on Expeller. Note:

10.

(a)

To assist assist in holding holding the last O-Ring O-Ring in position which which seals against the Impeller, apply heavy grease to the O-Ring groove.

(b)

All the O-Rings in their respective grooves will be compressed and fully covered by these metallic parts when the impeller is screwed onto the Shaft.

Liberally grease Shaft thread. Do not apply excessive grease as this could prevent the impeller from screwing on fully.

 Assembly of the remaining parts follows normal practice. Refer to the relevant Warman maintenance supplement.

3.

APPLICATION Centrifugal shaft sealing is usually applied when abrasive or corrosive slurries are

pumped. It has the following advantages compared with the packed gland seal: • 

no sealing water is required no dilution of the slurry occurs less wear on the shaft sleeve occurs less wear on the packing occurs

•  •  •  • 

less maintenance is required When the centrifugal seal is combined with gland flushing water, the gland requires lower pressures than a gland sealed pump and consequently is a lower maintenance option. In general, pumps with centrifugal sealing absorb approximately 3% more power than a gland sealed pump.

 Ap pl ic ati on wi th Stan dard dar d Im peller pel ler s The type 'HS' Centrifugal Seal can be used in any application where the older style centrifugal centrifug al seal was used in combination combinati on with standard impellers with back vanes. Due to the larger expeller diameter and special vane configuration the 'HS' seals have better sealing characteristics characteristics than the old style centrifugal seals. Tested performance performance curves for the 4/3-AH, 6/4-AH and 8/6-AH pumps fitted with standard 5 vane closed impellers and type ‘HS’' centrifugal seals are attached. For example: for the 8/6-AH pump with type 'HS' centrifugal seal (performance curve CSP86A01HS) at a flowrate of Q = 220 L/s and speed of rotation N   1100 r/min, the maximum inlet gauge pressure for no seal leakage operation is 170 kPa, assuming an impeller-throatbush impeller-throatbus h clearance of 0.2 mm. =

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 Ap pl ic ati on wi th Hig h Effi Ef fi ci ency enc y Im peller pel ler s (i mp ell ers wi th ou t b ack vanes) van es) Impeller back vanes vanes form an integral part of standard Warman Warman centrifugal seals. seals. Although the type 'HS' expellers have much improved sealing characteristics, it is not possible to achieve a no leakage operation in combination with impellers without back vanes. Therefore, to keep the slurry away from the gland, flushing water should be connected to the connection on the expeller expeller ring. The required pressure pressure of the sealing water can can be determined using the attached curves and the following procedure. (a)

Read the gland water water pressure pressure at zero static inlet head ((GWPO) GWPO) a att the given given duty flowrate and speed of rotation from the curves.

(b)

The required required sealing sealing water water pressure pressure at the gland (SW (SWP) P) for a highe higherr inlet head can can be found using equation (1).

SWP = GWPO + 1.3 STIP (kPa)

Equati on (1) 

SWP is the:sealing water pressure at the gland GWPO.is the gland:water pressure.at.zero inlet head STIP is the:availablestatic the:availablestatic inlet pressure (kPa)

For example using performance curve CSP86A07HS (8/6-AH pump) at a flowrate of Q 200 L/s and speed of rotation N = 1100 r/min, the gland water pressure at zero static inlet pressure GWPO GWPO = 61 kPa. If the static inlet pressure pressure STIP = 30 kPa, the required required flush water pressure will be FWP = 61 + 1.3 x 30 = 100 kPa. The application of water flushed centrifugal seals has the following benefits: •  • 

the expeller reduces pressure on the shaft seal lowering the required flush water pressure the flush water dilutes slurry in the expeller chamber reducing expeller and

expeller ring wear •  •  • 

flush and prolongs thepump life of is the packing flush water water provides prevents cooling slurry leakage when the not running flush water prevents slurry build up on expeller and blocking of vanes

The recommended flush water flow rates for each frame size are listed in Table 2. Frame si ze

A

B

C

D

E

F

G 

Flow rate (L/min)

0.8

1.0

1.5

2.0

4.0

6.0

9.0

Table 2: Flush water flow rates rates required for type 'HS' centrifugal se seal al and impellers wi without thout back vanes (Type HE, HN, BF and BR impellers).

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Figure 1 Type ‘HS’ ‘HS’ Centrif ugal Seal Seal Assembl y

Impellerr adjust ment Impelle The impeller is normally adjusted forward the same way as in a gland sealed pump and as described in the Warman Product Modification Advise PMA 110-102. The performance of the centrifugal seal can be increased somewhat by adjusting the impeller backwards. backwards. Such non-standard non-standard adjustment adjustment may be indicated indicated in applic applications ations where a high intake head makes makes the centrifugal seal’s per performance formance marginal. marginal. The price to pay for the gain in seal performance is increased wear and a slight to moderate drop in

head and efficiency.

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Figure 2 Warman Warman Pump 10/8 F-AH with Hi-Sea Hi-Seall Component s Diagram

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 APPENDIX 1 REQUIREMENTS FOR THE GLAND WATER SUPPLY & 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. The most common problems are:SUSPENDED AND DISSOLVED SOLIDS

Water quality is an extremely extremely important factor in gland seal op operation. eration. 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: Dissolved: Suspended:

1,000 ppm (mg/L) 100 ppm (mg/L)

100 % of +250 mesh (60 µm) particles removed. Maximum Ma ximum Indiv idual Dissolved Ions:  

Hardness (Ca+, Mg+) 200 ppm (mg/L) as CaCO3  Calcium Carbonate (CaCO3) 10 ppm (mg/L) Sulphate (SO4-) 50 ppm (mg/L) Chloride (Cl-) 1,000 ppm (mg/L) INADEQUATE OR EXCESSIVE GLAND WATER PRESSURE

Inadequate pressure pressure results in contamination contamination of the packing by the pu pumped mped slurry. Once solids are imbedded in the packing, they cannot be flushed out and the packing must be replaced. Seal water pressure should be 35 - 70 kPa above the stuffing box pressure. Pressure in excess of this only results in more wear on the packing and shaft sleeve. 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 control to each pump. In this case, the low pressure pump takes all the 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 a 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.

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Figure 3 Typical Centrifugal Seal Performance Curves

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BASIC BA SIC NU NUMBERS MBERS AND PARTS L LIST IST I 

B 

Impeller Release Collar (239), 6, 7

Basic Part Number 028, 5

L 

E  Expeller (028HS1), 6, 7, 8

Labyrinth (062), 6, 7

Expeller Ring (029HS1), 5, 7

Lantern Ring (063 [HS1]), 6

Expeller Ring Lifting Beam (310) , 7

Lantern Ring (063HS1), 5, 7

O 

F  Frame Plate Liner Insert (041HS1) , 5

O-Ring (109 or 064) , 8

P 

G  Packing Ring (111), 6, 7

Gland (044), 7 Gland (044[HS1]), 6 , 6, 7

S 

Gland Bolts (045) Gland Clamp Bolts (126) , 6, 7 Grease Cup (-), 6, 7

Shaft Sleeve (075), 5, 6, 7

Grease Cup Adaptor (138), 6, 7

Shaft Spacer (117), 5

H  Hi-Seal Expeller (028HS1), 5

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 A s s emb  As em b l y & Main Mai n t enan en anc ce Instructions Supp uppleme lement nt ‘BA1 ‘BA 1’ He Heavy avyeDuty Bea Assembl y (Basic Number 005) 005) (Frame (Fram SizesBearin N, rings P, gs Q, Assembly R, R, S, T, U)

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

 

Office of origin :

Pump Technology Centre, Artarmon

Reference :

Pump Manuals

Date :

22 January 2007

Last Issued:

July 2005

 

Weir Minerals

| BA1 Heavy Duty Bearing Assembly Jan 07.doc 

Warnings Personnel injury and / or equipment damage could result from not observing the following IMPORTANT SAFETY INFORMATION. •   A 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, mechanical seals, etc) all related safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment   and maintenance. •   All guards  for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards should not be removed or opened while the pump is running. Personal injury may result from contact with rotating parts, seal leakage or spray. •  checked  before belts or couplings are connected. Driver rotation must b e checked •  Pumps must not be operated 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 high temperature and pressure created. •  Pumps must be used only within their allowable limits  of pressure, temperature and speed. These limits are dependent on the pump type, configuration and materials used. •  heat to t he impeller boss or  nose in an effort to loosen the impeller thread prior Do not apply heat 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. •  LIFTING of components • 

Tapped holes (for eye bolts) and lugs (for lifting shackles) on Warman pumps are for only . lifting Individual parts only.

• 

Lifting devices devices of adequate adequate capacity capacity must be used used wherever wherever they are are required to be used.

•

  Safe workshop should besuspended applied during all assembly and maintenance work. Personnel mustpractices never work under loads. •  The pump must be fully isolated   before any maintenance work, 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. •  • 

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Castings   made from materials listed are brittle and have low thermal shock resistance.

 Attempts to repair or rebuild by welding may cause catastrophic catastrophic failure. Repairs of such castings using these methods must not be attempted - A03, A04, A05, A06, A07, A08, A09,  A12, A14, A49, A51, A52, A53, A53, A61, A210, A211, A217, A217, A218, A509. •  Impellers  must be tight t ight on the shaft before any start-up, ie all components on the shaft between the impeller and the pump end bearing must butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking etc.

• 

Burning  of elastomer pump components will cause emission of toxic fumes and result in air

pollution which could lead to personnel injury. • 

Leakage from the pump shaft seals and/or leakage from worn pump components or seals may

cause water and/or soil contamination. contamination. • 

Liquid waste disposal  from servicing of pumps or stagnant water from pumps stored for long

periods, may cause water and/or soil contamination. •  Do not apply anti-seize compounds   to the impeller or shaft threads or to elastomer seals during assembly. Anti-seize can greatly reduce the impeller thread friction and may cause the impeller to loosen during pump shut-down and run-back resulting in pump damage, or the elastomer seals to leak at reduced pressure. •  This manual applies only to genuine Warman parts  and Warman recommended parts. •  Mixing of new and worn pump parts  may increase the incidence of premature pump wear and leakage. •  Large foreign objects or tramp  entering a pump will increase the incidence of higher wear and / or damage to the pump. Routine inspection and maintenance of mill trommel screens will assist to reduce the danger of grinding balls entering a mill discharge pump. •  Large variations in slurry properties may lead to accelerated rates of wear and corrosion of pump components eg •  Wear increases exponentially exponentia lly with velocity and slurry particle size. •  Corrosion rate doubles for every 10 degree Celsius increase in slurry temperature. temperature . •  Corrosion rate increases exponentially exponentiall y as slurry pH decreases.

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| BA1 Heavy Duty Bearing Assembly Jan 07.doc 

 

ISSUED: JA NUARY 2007

LA ST ISSUE: JULY 2005

WARMAN PUMPS

 ASSEMBLY AND MAINTENANCE MAINTENANCE INSTRU INSTRUCTIONS CTIONS SUPPLEMENT ‘BA1’

HEAVY DUTY BEARING ASSEMBLIES (BASIC NUMBER 005) (FRAME SIZES N, P, Q, R, S, T, U)

CONTENTS

WARNINGS

2 

CONTENTS

4 

1 

5 

INTRODUCTION  Ad vant ages and us es o f Heavy Heav y Du Duty ty Bearin Bear in g A ss embl ies  

2 

PARTS IDENTIFICATION

5 

3 

BEARING LUBRICATION

6 

4 

LA BYRINTH GREASE PURGING

8 

5   ASSEMB  ASSEMBLY LY INSTRUCTIONS Fittin g of Drive End Inner Bearing and Pump End B earing earing - See See Figure 1 

9  9 

Fittin g of Drive End Outer Ring Bearing to Bearing Housing - S See ee Figure 2 

11 

Fittin g Shaft to Bearing Hous ing - See Figure 3 

12 

Fitting Labyrinths, Piston Rings, Bearing Seal and Locknut - See Figure 4 

13 

6 

FITTING FITTIN G IMPELL IMPELLER ER RELEASE COLLAR

14 

7 

CHECKING BEA RING FITTED END PLAY PLA Y

14 

8 

TESTING

15 

9 

MAINTENANCE MAINTENA NCE STAND-BY STAND-B Y PUMPS

15 

BASIC BA SIC PART NUMBERS NUMBERS AND PARTS LIST

16 

RECOMMENDED RECOMMEN DED BEARING BEA RING GREASE

17 

23/01/2007

 

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© Copyright Weir Minerals Australia Ltd

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| BA1 Heavy Duty Bearing Assembly Jan 07.doc 

INTRODUCTION

Supplement 'BA1' should be read in conjunction with the appropriate Assembly and Maintenance Instruction Manual Supplement for the particular Type of Warman Pump when Heavy Duty Bearing Assemblies (as denoted by a single or double letter after the pump size eg. R, RS, T, TU etc.), are used.

 Ad vantag van tag es and an d u ses of Heavy Du ty Bearin Bear in g A ss embli emb li es   For the duties which require a high bearing capacity such as for large belt drives, multi-stage pumping (increased thrust loadings onto bearings) or in some cases where the pump is operating at or near its maximum speed and power, then the extra capacity of the Heavy Duty Bearing Assemblies will give significantly higher bearing life than a Basic or Modified Basic Bearing Assembly and therefore less downtime and maintenance costs. Other features of Heavy Duty Assemblies are: (a)

All threaded components are metric.

(b)

The drive drive end shaft shaft extension extension diameter is metric metric and and me metric tric ke keys ys are used.

(c)

No setting or adjusting of bearing end play is required such as is necessary on Basic Bearing Assemblies. Assemblies. Heavy Duty Bearing Bearing Assemblies are are fitted with a two row tapered roller bearing at the pump pump end. These two row bearings bearings are factory set set with the required amount of end play. Consequently no shimming during assembly is required.

(d)

Grease purged purged labyrinths labyrinths are standard to assist assist in exclusion exclusion of dirt and moistu moisture re from assemblies.

2

PARTS IDENTIFICATION

Every Warman part has a name and a three-digit three-digi t Basic Part Number. Parts with the same name, irrespective of size, have the same Basic Part Number. Thus the shaft of every Warman pump has the Basic Number 073.  Additional letters and digits are added before and after a given basic number to identify a specific component part of a particular pump. This then becomes the part number of that component. Every part has its part number cast or otherwise marked on. Most parts for Heavy Duty Bearing Assemblies will begin with a single letter. For example: S073M = Shaft for S005 Bearing Assembly. For full description and part number identification, refer to the appropriate Warman Components Diagram. Names and and Basic Numbers are used in assembly instructions in this ma manual. nual. The relevant Basic Numbers are listed at the end of this supplement (Basic Part Numbers and Parts List). 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 misunderstand ings or wrong deliveries. When in doubt, the pump serial number should be quoted as well.

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| BA1 Heavy Duty Bearing Assembly Jan 07.doc 

BEA BEARING RING LUB LUBRICATION RICATION

It is recommended that lubricating grease used in rolling bearings should have the following characteristics:  A lithium complex soap soap thickener thickener grease with EP additives additives and oxidation oxidation inhibitors inhibitors.. N. L. G. I. Consistency No ...........................2 Drop Point ................................................... ........................... ........................ 260°C Work penetration @ 25°C (A.S.T.M.) ..........265 to 295 RECOMMENDED BEARING GREASE MOBIL HP or equivalent.  A correctly assembled assembled and pre-greased pre-greased bearing assembly, assembly, (see Assembly Assembly Instruc Instructions) tions) will have a long trouble free life, provided that it is protected against ingress of water or other foreign matter and that it is adequately adequately maintained. maintained. Careful attention paid to purging of the llabyrinth abyrinth (refer to Labyrinth Grease Purging) with grease will provide extra protection against ingress of dirt and prolong bearing life. It is necessary for the maintenance personnel, to open the bearing housing at regular intervals (not longer than twelve months) to inspect bearings and grease and to then determine each time the course of action for the period up to the next inspection. inspection. This is the preferred method of assessing the actual condition of the bearings and the effectiveness of the lubrication applied.

The frequency and amount of lubricant to be added periodically depends upon a number of factors and a combination of them, including speed and size of bearing, duration and extent of on-off operation, and the usual environmental conditions such as ambient and operating temperatures, splash and the presence of contaminants. If a regular addition of grease is judged necessary, or for unusual circumstances where extreme conditions warrant additional lubricant lubricant to be supplied, the plugs on the bearing assembly maybe replaced with grease nipples although this practice is not highly recommended. Grease nipples must be cleaned prior prior to use, to prevent ingress of dirt into the bearings whi whilst lst greasing. It is preferable to lubricate often and sparingly, than to add large amounts at long intervals. Bearings must never be overgreased. Excess Grease: Grease: The immediate effect of an excess of grease within within a bearing is overheating due to the churning of of the grease. grease. This particularly particularly is to be avoided. avoided. If bearings run too ho hott after a change of grease, the trouble is likely to be due to overgreasing. Under no circumstances  add more lubricant to correct the overheating. Most pump bearings operate in the lower speed ranges but there is still the risk of damage due to over-lubricating over-lubricating especially especially in the case of the smaller smaller sized bearings. bearings. Such cautiona cautionary ry measures to avoid over-lubrication, however, do not warrant neglecting the bearings ementt and exp eri erienc enc e should be the final determining factors in completely. Therefore,  ju dg emen establishing routine routine lubrication procedures. procedures. Consequently Consequently it is advisable to observe the bearing frequently at the outset of operations taking careful note of any unusual conditions regarding temperature and cleanliness. cleanliness.

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Weir Minerals

| BA1 Heavy Duty Bearing Assembly Jan 07.doc 

For ordinary conditions of continuous operation where bearing operating temperatures do not exceed the temperature where the grease loses its ability to seal, the guidelines tabulated below can be used. Use only recommended, clean grease. 

SUGGESTED LUBRICATION INTERVAL FOR BOTH PUMP AND DRIVE END BEARINGS (Hours) FRAME BEARING

PUMP SPEED SPEED (r/mi (r/min) n)

Add Gram Per

20 200 0

40 400 0

60 600 0

80 800 0

10 1000 00 12 1200 00 14 1400 00 16 1600 00 18 1800 00 20 2000 00 22 2200 00 30 3000 00 38 3800 00

BRG    

N

N009

20

 —

—

—

—

 

P

P009

30

 —

—

3100

2200

1700 1400 1200 1000 900

800

Q

Q009

55

 —

—

2500

1800

1400 1100 900

750

650

R

R009

85

 —

3200

2000

1400

1100

800

620

500

S

S009

115

 —

2600

1500

1000

700

480

—

T

T009

250

 —

2000

1200

700

—

—

U

U009

490

40 4000 00

15 1500 00

70 700 0

—

—

—

N

N009D

15

 —

—

—

—

P

P009D

20

 —

—

 

2300 1800 1600 1400 1200 1050 900

650

500

700

—

—

550

500

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

10000 8500 7500 6000 5500 4900 4500 3000 2000

16000 12000 9000 7000 6500 5100 4800 4000 3500

—

—