MDS23 Quick Change Out Removal 400 to 750 M Series Frames SET2010[1]

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

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

WARMAN ASSEMBLY INSTRUCTIONS QUICK CHANGE OUT REMOVAL AND INSTALLATION WARMAN “M STYLE” FRAMES (SIZES 400 thru 750 MCR)

Ron Bourgeois / Mike Viken Product Development Manager / Senior Designer © Weir Slurry Group Inc., 2010. Weir Slurry Group Inc. are the owners of the Copyright subsisting in this document and these designs, specifications and instructions. The document may not be reproduced or copied in whole or in part in any form or by any means without the prior consent in writing of Weir Slurry Group Inc.

Office of origin: Weir Minerals North America

Reference: Manual Supplement MDS23

Date: Sept 14, 2010

Last Issued: Initial Release

Weir Minerals North America | MCR QUICK CHANGE OUT REMOVAL AND INSTALLATION INSTRUCTIIONS

CONTENTS 1. Introduction and Safety

2. Quick Change Out Assembly Instructions Page

Worn Wet End Removal Instructions ------------------------------------------------- 9 -12

New Wet End Installation Instructions ----------------------------------------------- 13 -18

Required crane capacity and sling details ----------------------------------------- 19 1. Introduction and Safety Warman® centrifugal slurry pumps, when properly installed and operated, and when given reasonable care and maintenance, will operate satisfactorily for a long period of time. The following paragraphs outline the general principles that should be considered to ensure trouble-free pump operation. Warman® slurry pumps are built in a variety of designs and materials and for many different slurry services. The manufacturer’s instruction book should be studied carefully and followed, as there may be specific requirements for a particular machine or application that cannot be covered in a general discussion. The installation and service manual and/or special instructions included in the shipment should be read thoroughly before installing or operating the pump. All instructions regarding maintenance should be retained for reference. Marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform to the applicable CE (European conformity) marking directives covering machinery and, where applicable, low-voltage equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED), and equipment for potentially explosive atmospheres (ATEX). Where applicable, the directives and any additional approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable, this document incorporates information relevant to these directives and approvals. To confirm the approvals applying and if the product is CE marked, check the serial number plate markings and the certification.

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Safety Legal requirements and local regulations may differ substantially with regard to particular safety requirements and may be regularly modified by relevant authorities without notice. As a consequence, applicable laws and regulations should be consulted to ensure compliance. The following cannot be guaranteed as to its completeness or continuing accuracy. Explanation of safety terminology and symbols These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are: This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life. This symbol indicates safety instructions where non-compliance will involve a high risk to personal safety or the loss of life. This symbol indicates safety instructions where non-compliance would affect personal safety and could result in the loss of life. This symbol indicates safety instructions where non-compliance may result in minor or moderate personal injury and/or damage to the equipment or property. This is a general safety alert symbol to indicate the potential risk of personal injury and/or damage to the equipment or property.

This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would affect personal safety and could result in loss of life. This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion. This sign is not a safety symbol but indicates an important instruction in the assembly and/or operation process.

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General guidelines These Instructions must always be kept close to the pump’s operating location or directly with the pump. Warman® slurry pumps are designed, developed and manufactured with state of the art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements.

Weir Minerals is committed to continuous quality improvements and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements, applicable safety and health laws/regulations.

These Instructions should be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety noted in the instructions have been met. Information in these User Instructions is believed to be reliable. In spite of all the efforts to provide sound and all necessary information, the content of this manual may appear insufficient and is not guaranteed as to its completeness or accuracy. For the safety of operating personnel, please note that the information supplied in this manual only applies to the fitting of genuine Warman parts and Warman recommended bearings to Warman® slurry pumps. Weir Minerals manufactures products to exacting International Quality Management system Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Weir Minerals cannot test parts and accessories sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized parts and accessories is considered misuse. Damage or failure caused by misuse is not covered by our warranty. In addition, and modification of Weir Minerals products or removal of original components may impair the safety of these products in their use.

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The pumps must not be operated beyond the allowable limits of pressure, temperature and speed specified for the application. These limits are dependent on the pump type, configuration and materials used. If there is any doubt as to the suitability of the product for the application intended, contact Weir Minerals for advice, quoting the serial number. If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty), it is requested that the user seek the manufacturer’s written agreement before start up. Personnel qualification and training All personnel involved in the operation, installation, inspection, and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer/supplier to provide applicable training. Always coordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws and regulations. Safety action This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and to equipment.

WEIR MINERALS WOULD LIKE TO BRING TO YOUR ATTENTION THE POTENTIAL HAZARD CAUSED BY THE CONTINUED OPERATION OF CENTRIFUGAL PUMPS WHEN THE INTAKE AND DISCHARGE ARE BLOCKED. EXTREME HEAT IS GENERATED AND RESULTS IN VAPORIZATION OF THE ENTRAPPED LIQUID. THIS CAN RESULT IN A LIFE THREATENING EXPLOSION. The operation of centrifugal pumps on slurry applications can increase this potential hazard due to the nature of the material being pumped. The additional hazard believed to be presented by slurry applications stem from the possibility of solids blocking the pump discharge and remaining undetected. This situation has been known in some instances to lead to the intake side of the pump also becoming blocked with solids. The continued operation of the pump under these circumstances can be extremely dangerous. If you have an installation that may be prone to this occurrence, we suggest you adopt measures to prevent this blockage situation The WARMAN® CENTRIFUGAL SLURRY PUMP is a piece of ROTATING EQUIPMENT which CONTAINS PRESSURE under service conditions. All standard safety precautions for such equipment should be followed before and during installation, operation, and maintenance.

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

For pumps fitted with MECHANICAL SEALS always follow the appropriate instruction manuals and ALWAYS REMOVE THE MECHANICAL SEAL SETTING TABS PRIOR TO STARTING THE PUMP. Failure to remove the setting tabs will result in damage to both the pump and the seal.

DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS for prolonged periods (three minutes is considered maximum), OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORIZE. Personal injury and equipment damage could result from the high temperature and pressure created.

DO NOT APPLY HEAT TO THE IMPELLER BOSS OR NOSE IN AN EFFORT TO LOOSEN THE IMPELLER THREAD PRIOR TO IMPELLER REMOVAL. Personal injury and damage to equipment could occur as a result of an explosion. A shaft wrench has been provided to assist impeller removal. In some cases, a release collar has also been provided to assist impeller removal.

DO NOT OPERATE THE PUMP without properly installed stuffing box, v-belt and coupling guards in place. All guards for rotating equipment must be correctly fitted before operating the pump including guards temporarily removed for gland inspection and adjustment. Seal guards must not be removed or opened while the pump is running.

DO NOT OPERATE THE PUMP if solids have settled and the rotating element can not be turned by hand. THERMAL SHOCK Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal shock may cause damage to the internal components and rupture the pump casing. DRIVER ROTATION MUST BE CHECKED to match correct pump rotation direction as marked on the pump casing before belts or couplings are connected. Do not touch rotating members with your hand to establish the direction of rotation. Always check the direction of the pump shaft and not the gearbox input shaft which is in the opposite direction and will be in the wrong direction for the pump. DO NOT START A PUMP that is rotating in reverse, such as the backward rotation caused by slurry runback. Personal injury and damage to equipment could result.

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ENSURE THAT THE IMPELLER IS TIGHT ON THE SHAFT before any start-up, i.e. all components on the shaft between the impeller and the pump end bearing are 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. ENSURE CORRECT LUBRICATION Some equipment such as gear reducers, motors, and oil lubricated pump bearing assemblies are shipped without lubricating oil. Be certain that oil of the proper grade is filled to the proper level in each piece of equipment before start-up. NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER. Power to the electric motor must be isolated and tagged out. THE PUMP MUST BE FULLY ISOLATED before any maintenance work, inspection or troubleshooting involving work on sections which are potentially pressurized (e.g. casing, gland, connected pipe work) or involving work on the mechanical drive system (e.g. shaft, bearing assembly, coupling). It must be proven that the intake and discharge openings are totally isolated from all potentially pressurized connections and that they are, and can only be exposed to atmospheric pressure.

DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous.

• • • •

HANDLING COMPONENTS Worn pump components can have sharp or jagged edges. Caution must be taken in handling worn parts to prevent damage to slings or personal injury. Lifting devices of adequate capacity must be used whenever they are required. Safe workshop practices must be applied during all assembly and maintenance work. Personnel must never work under suspended loads.

DO NOT APPLY HEAT OR HARD-FACE HIGH CHROME COMPONENTS. This can cause cracks, residual stresses, and changes the fracture toughness of the parent material. This may lead to catastrophic failure and could result in personal injury and equipment damage even when operating within recommended speed and pressure limits.

CASTINGS made from materials listed are brittle and have low thermal shock resistance. Attempts to repair or rebuild by welding may cause catastrophic failure. Repairs of such castings using these methods must not be attempted. Examples include, but are not limited to the following - A03, A04, A05, A06, A07, A701, A08, A09, A12, A14, A49, A51, A52, A53, A61, A124, A210, A211, A217, A218, A238 and A509.

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• • •

AVOID CONTAMINATION BURNING of elastomeric pump components will cause emission of toxic fumes and result in air pollution which could lead to personal injury. LEAKAGE exceeding the specified packing lubrication requirements from the pump shaft seals and/or leakage from worn pump components or seals may cause water and/or soil contamination. LIQUID WASTE DISPOSAL from servicing of pumps or stagnant water from pumps stored for long periods, may cause water and/or soil contamination.

Mixing of NEW AND WORN PUMP PARTS may increase the incidence of premature pump wear and leakage. All METAL MATING FACES MUST BE CLEANED of dirt, rust, paint and other adhering substances prior to pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to catastrophic failure of parts.

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, e.g. • Wear increases exponentially with velocity and slurry particle size. • Corrosion rate doubles for every 10 degrees Celsius (18 degrees Fahrenheit) increase in slurry temperature. • Corrosion rate increases exponentially as slurry pH decreases.

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WORN WET END REMOVAL INSTRUCTIONS

1. Keep the bearing assembly in its current position and remove discharge and suction piping. 2. Remove coupling guard. 3. Remove gland guard and disconnect gland water piping. 4. Remove two piece gland, packing and stuffing box mounting bolts. 5. With the lantern ring still installed inside the stuffing box, slide stuffing box back towards bearing assembly as far as possible. Then slide it forward about 75mm (3.0”). This will position the lantern ring in the middle of the stuffing box for support. NOTE: Stuffing box will remain on the shaft sleeve throughout the procedure. 6. Using a custom made four (4) leg sling support the wet end with an overhead crane. Refer to Table 1 on page 19 for estimated weights, chain lengths and pick points depending on the specific discharge position. IMPORTANT: Make certain the crane has the required load capacity to lift the wet end mass noted on Table 1 on page 19. 7. While looking down the discharge measure the suction side gap between the throatbush and impeller and the drive side gap between the frame plate liner insert and the impeller. NOTE: Check the suction eye gap also and use the lesser of the two for the bolt length calculation in the next step. Refer to Figure D on page 12. 8. Confirm throatbush pusher bolts are long enough to clamp impeller. Length required will be approximately the estimated throatbush to impeller gap “A” plus frame plate liner insert to impeller gap “B”. Refer to Figure A. 9. Remove frame plate stud nuts. Refer to figure D on page 12.

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10. Loosen the throatbush puller nuts as far as possible, but do not remove the nut and washer from the stud. Refer to Figure B. 11. Pick two throatbush pusher bolts 180 degrees apart and alternate tightening one bolt at a time so the throatbush does not tilt and become locked in cover plate pilot. IMPORTANT: Tighten each bolt no more than one and a half turns at a time. TIP: Mark a reference line on the O.D. of the socket to assist with the number of turns. 12. Attach the shaft wrench to the drive end of the shaft. Refer to Figure C. Using the gap measurement from step 7 as a reference length, continue adjusting throatbush towards the impeller. Maximum adjustment should not exceed 75mm (3.0”). NOTE: Initial contact with the impeller can be confirmed by checking if the shaft will rotate freely. Once the throatbush contacts the impeller, continue adjusting the throatbush pusher bolts to allow the frame plate liner insert to contact the impeller. NOTE: Depending on the amount of wear the complete wet end may begin to move towards the suction tank creating a gap between the adapter and frame plate pilot. Refer to Figure B. Confirm the frame plate liner insert and impeller are in contact by looking down the discharge. NOTE: EL1 impellers have sloped back shroud and depending on wear patterns a gap of 13mm (.50”) may be present at the O.D. of impeller while looking down the discharge. Contact on these impellers is made closer to the hub and cannot be seen from discharge. Inability to turn the shaft confirms impeller contact.

13. Once the frame plate liner insert and the impeller have made contact and the shaft no longer rotates freely. IMPORTANT: Continue to adjust the throatbush pusher bolts forward one complete turn to compress the rubber and fully clamp the impeller. 14. Using the shaft wrench break the impeller free by striking shaft wrench with a hammer blow. NOTE:: If hammer blow does not break the impeller free, follow the instruction in Warman Supplement ‘M2’ on Impeller Release Collar Installation and removal. 15. Using the hex at the end of the frame plate studs loosen all studs until they disengage from the frame plate and remove. Refer to Figure C.

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16. Rotating the shaft will jack the complete wet end assembly away from the drive end, move overhead crane to allow the shaft to be turned by hand. Continue turning until the shaft disengages from the impeller and the complete wet end is clear. 17. Remove stuffing box and inspect for damage. 18. Inspect shaft sleeve and lantern ring for possible wear.

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NEW WET END INSTALLATION INSTRUCTIONS NOTE: Apply an anti-seize lubricant to threads of any bolts, studs or nuts to assist with future pump dis-assembly.

1. Inspect and install shaft sleeve with o-rings onto shaft. Install lantern ring over shaft sleeve. NOTE: Make certain tapped holes in lantern ring are facing the bearing housing. Install stuffing box over shaft sleeve and lantern ring and slide them back towards the bearing assembly as far as possible. 2. Install the frame plate liner insert (FPLI) and frame plate liner with all the appropriate hardware and place the frame plate bowl-up on the floor. (Refer to Warman supplement MDS18 for procedures on correctly installing these parts for specific model size.) 3. Loosen the FPLI pusher bolts and fully tighten the puller stud nuts. This will ensure the FPLI is flush against the frame plate. NOTE: There will be a visible mismatch between the frame plate liner and the FPLI as shown in Figure 1 Detail A. 4. Secure the frame plate liner with adhesive tape at the approximate locations shown in Figure 1. 5. Install two casing alignment Pins. (See appropriate component diagram for location based on discharge position.) 6. Using two equal length chains rig the impeller through the inlet. Using a one point pick lift and lower the impeller hub into the FPLI bore. IMPORTANT: Position the impeller as concentric as possible with the outer diameter of the FPLI.

VISABLE MISMATCH

METAL TO METAL CONTACT

DETAIL A

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7. Install the cover plate liner with all the appropriate hardware into the cover plate. (Refer to Warman supplement MDS18 for procedures on correctly installing these parts for specific model size.) 8. Secure the cover plate liner in place with adhesive tape similar to frame plate in Figure 1. 9. Using a three point pick lower the cover plate sub-assembly onto the frame plate as shown in Figure 2. 10. Insert the cover plate stud with the anti-rotation nut assembled from the back of the frame plate as shown in Figure 2. Install a washer and nut to each cover plate stud. Thread nuts on fully by hand before using impact wrench. NOTE: On some models the Cut-Water Stud may be larger than the Cover Plate Studs. (Refer to Warman Supplement MDS18 for the torque specification for specific model size.) 11. Install (16) suction cover studs into the cover plate and fully tighten as shown in Figure 2.

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12. Install the throatbush with all the appropriate hardware onto the suction cover. (Refer to Warman supplement MDS18 for procedures on correctly installing these parts for specific model size.) 13. Using a three point pick lower the suction cover and throatbush sub-assembly into the cover plate as shown in Figure 3. IMPORTANT: Take caution to align the (8) clearance holes in the suction cover with the cover plate liner studs as shown in Figure 3 detail B. NOTE: For size 750 MCR make certain the lifting lugs on the suction cover and adapter plate are in the 12 O’clock position depending on the discharge orientation. Refer to Table 1 on Page 19. Fit a washer and nut to each suction cover stud. (Refer to Warman Supplement MDS18 for the torque specification for specific model size.) 14. Install the throatbush pusher bolt and hand tighten.

DETAIL B

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15. Loosen the throatbush puller nuts approx. 19mm (.75”). Pick two throatbush pusher bolts 180 degrees apart and alternate tightening one bolt at a time so the throatbush does not tilt and become locked in cover plate pilot. IMPORTANT: Tighten each bolt no more than one and a half turns at a time. TIP: Mark a reference line on the O.D. of the socket to assist with the number of turns. Refer to Figure 4. 16. Confirm the throatbush and impeller have made contact by running a long feeler gauge around the suction eye between the impeller seal face and the throatbush. Once the throatbush has contacted the impeller as shown in Figure 5. IMPORTANT: Continue to adjust the throatbush pusher bolts forward one complete turn to compress the rubber and fully clamp the impeller. NOTE: Preload on the impeller has now been established. 17. Tighten the throatbush puller nuts against the cover plate.

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18. IMPORTANT: Check to insure that the impeller o-ring has been installed. Refer to Figure 6. 19. Using a custom made four (4) leg sling lift the complete wet end assembly to the vertical position. Refer to Table 1 on page 19 for estimated weights, chain lengths and pick points depending on the specific discharge position. IMPORTANT: Make certain the crane has the required load capacity to lift the wet end mass noted on Table 1 on page 19. 20. Begin turning the shaft wrench while slowly moving the wet end towards the bearing assembly. Once the impeller thread has engaged the shaft continue turning the shaft wrench until the frame plate and adapter pilots have engaged. NOTE: If the pilots have engaged continue turning the shaft wrench until the impeller has made contact with the shaft sleeve. Strike the shaft wrench several times to fully clamp the shaft sleeve and continue to step 23. IMPORTANT: If the pilots are not engaging and are misaligned and the impeller has not contacted the shaft sleeve. Execute step 21 and step 22 to align frame plate and adapter pilots. 21. Remove the preload on the impeller. Loosen the throatbush pusher bolts approx. 25mm [1.0”]. Tighten the throatbush puller nuts using a crossing pattern until the throatbush is tight against the suction cover as shown in Figure 6. 22. Using small crane adjustments align the pilots until they have engaged. IMPORTANT: Reapplying preload. Loosen the throatbush puller nuts approx. 25mm (1.0”). Pick two throatbush pusher bolts 180 degrees apart and alternate tightening one bolt at a time so the throatbush does not tilt and become locked in cover plate pilot. IMPORTANT: Tighten each bolt no more than one and a half turns at a time. Once the throatbush and the impeller have made contact and the shaft no longer rotates freely continue to adjust the throatbush pusher bolts forward one complete turn to compress the rubber and reset the preload. Continue turning the shaft wrench until the impeller has made contact with the shaft sleeve. Strike the shaft wrench several times to fully clamp the shaft sleeve and continue to step 23. 23. IMPORTANT: Remove the preload on the impeller. Loosen the throatbush pusher bolts approx. 25mm [1.0”]. Tighten the throatbush puller nuts using a crossing pattern until the throatbush is tight against the suction cover as shown in Figure 6. NOTE: Tighten each nut no more than one and a half turns at a time. 24. IMPORTANT: Slowly release the load on the four (4) leg sling. This will allow the pilot on the frame plate to seat fully into the pilot in the frame plate adapter. 25. Using the hex on the end of the frame plate studs align the holes in the frame plate adapter and thread the studs into the frame plate. Install a nut to each stud. NOTE: Small crane adjustments may be necessary to align studs. 26. Fully tighten the frame plate nuts using a crossing pattern to the torque specified in Warman supplement MDS18. 27. Loosen the FPLI puller nuts approx. 25mm [1.0”]. With someone looking down the discharge tighten the FPLI pusher bolts using a crossing pattern until the FPLI is flush with the frame plate liner as shown in Figure 6. NOTE: This will set the back shroud clearance gap. 28. Refer to Warman supplement MDS18 for setting impeller to throatbush clearance. 29. Refer to Warman supplement MDS18 for stuffing box centering and assembly procedure. 09/14/2010

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