The Orion Series of Horizontal Slurry Pumps HM100 MHC-D

Operation & Maintenance Manual
The Orion Series of Horizontal Slurry Pumps
HM100 MHC-D
Pump No
26172301001
Supplier / Order No
Metso Minerals (Norway) Ltd. / 54965
Customer Name
Smedvig Offshore A/S
Note!
This pump is intended for use in
ATEX hazardous area Class II 3 G
Note!
This pump is equipped with mechanical shaft sealing.
Mechanical seals must never run dry!
Ensure that the pump is filled with liquid before start, see chapter 9.5.3 for details.
If the seal run dry it will be destroyed within seconds.
2006-07-11
Slurry Pump
0
EXPLOSIVE ATMOSPHERE (ATEX) – SUPPLEMENT
0.1
About this supplement
The instructions provided in this supplement apply to pumps intended for use in ATEX
hazardous areas.
They complement the standard instructions presented in the accompanying Operation &
Maintenance Manual, but in case of any contradiction, they shall override the latter.
0.2
General information about ATEX
ATEX
ATEX is not a standard but an acronym for 'ATmosphères
EXplosifs'. It stands for the European Directive 94/9/EC
covering the certification procedures for equipment destined
for use in hazardous areas.
Explosive atmosphere
A mixture of flammable substances in the form of gas, vapour,
mist, dust or fibres, and air under atmospheric conditions, in
which, after ignition, combustion spreads throughout the
unconsumed mixture.
Maximum surface
temperature
The highest temperature attained in service, under the most
adverse operating conditions expected within the pump
equipment rating, by any part or surface of the equipment, that
could ignite the surrounding explosive atmosphere.
0.3
Supplementary instructions
0.3.1
Supplement to section 2.1.1 ‘Product signs’ (Chapter 2)
- CE marking
- European Commission mark for EX-products
- Equipment group: Surface
- Equipment category
- Gas
Figure 2.1.1-x Machine plate
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ATEX-Supplement
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Slurry Pump
0.3.2
Supplement to section 3.1.2 ‘Training’ (Chapter 3)
For your own personal safety, read and take note of the following:
HAZARDOUS AREAS
- This pump is intended for use in areas in which
explosive atmospheres created by gases, vapours,
mists or air/dust mixtures are likely to occur.
0.3.3
Supplement to section 5 ‘Control sytem’ (Chapter 5)
(NOT APPLICABLE)
0.3.4
Supplement to section 7 ‘Commissioning’ (Chapter 7)
1.
Check that the electrical engine is approved for ATEX hazardous area.
2.
Ensure that the pump installation is equipped with a level sensor or similar to prevent
it from running dry.
3.
BEFORE
4.
Ensure that the pump pipework is equipped with devices that would prevent high
temperatures, or high pressures, caused by ”closed valve conditions”.
5.
Make sure that all other installed equipment is approved for ATEX hazardous area.
6.
Check that the pump is properly grounded.
0.3.5
starting the pump, make sure it is primed.
Supplement to section 8.3 ‘Running checks’ (Chapter 8)
During pump operation, the following conditions need to be continuously monitored by a
control system.
NOTE: THE CONTROL SYSTEM IS NOT INCLUDED IN THIS SUPPLY.
•
0.3.6
A level system that ensures that the pump never run dry.
Supplement to section 9.2.1 ‘Routine maintenance’ (Chapter 9)
ITEM
Bearing cylinder
ACTION
Check bearing for over-heating
Shaft seal
Check for over-heating
100h
Pump/Drive unit installation
Check for right pump shaft speed
100h
ATEXII3Gen_01a.doc
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04-W16
RUNNING HOURS
100h
ATEX-Supplement
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Slurry Pump
EXPLOSIVE ATMOSPHERE (ATEX) - SUPPLEMENT
0.1
0.2
0.3
1.
GENERAL
1.1
1.2
1.3
1.4
2.
About this supplement
General information about ATEX
Supplementary instructions
About this manual
Transport and storage
Pump specification
Customer service
DESCRIPTION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Product and warning signs
Applications
Design
Materials and maximum working pressures
Surface treatment
General arrangement
Performance curves
Certificates & test results
3.
HEALTH & SAFETY
4.
DESCRIPTION OF OPERATION
5.
CONTROL SYSTEM
6.
INSTALLATION
6.1
6.2
6.3
6.4
6.5
6.6
6.7
General
Foundation requirements
Installation tools and equipment
Installation procedure
Pipe connections & pump sump
Shaft gland
Motor and operation
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Content
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Slurry Pump
7.
COMMISSIONING
8.
OPERATING INSTRUCTIONS
8.1
8.2
8.3
9.
Starting
Stopping
Running checks
CARE AND MAINTENANCE
9.1
9.2
9.3
9.4
9.5
9.5.1
9.5.2
9.5.3
9.5.4
9.5.5
9.5.6
Safety measures
Preventive maintenance & service schedule
Tools and special equipment for service and maintenance
Lubrication instructions
Dismantling and assembly
Setting pump clearances
Hydraulic parts and frame - removal and fitting
Shaft seal – removal and refitting
Shaft and bearing assembly - removal and fitting
Shaft and bearings - disassembly and re-assembly
Pump drive - dismantling and reassembling
9.6
Fault tracing schedule
10. SPARE PARTS
10.1 Recommended stock of spares
10.2 Storage of spare parts
10.3 Spare parts ordering procedure
10.4 Spare parts drawing
10.5 Parts list
10.6 Special tools
11. APPENDICES
11.1 Torque table
11.2 Reference publications list
11.3 Weights table
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Content
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Slurry Pump
1
GENERAL
1.1
About this manual
This manual is a part of the equipment to which it relates. It is written for the use of
installers, commissioning engineers, operators and maintainers. It should be kept for the
life of the equipment and, in case of re-sale, passed on to any subsequent purchaser.
Information contained in this manual is specific to the equipment and is correct at the date
of publication. As improvements are continually being made, Metso Minerals reserve the
right to make alterations to the equipment design and specification without giving prior
notice. Any amendments issued by Metso Minerals should be promptly inserted into this
manual.
© 2004 — Metso Minerals (Sala) AB. The contents of this manual must not be
reproduced without the prior written permission of Metso Minerals (Sala) AB.
1.2
Transport and storage
1.2.1
Delivery
A pump is either dispatched as an individual unit (bare shaft pump) or mounted complete
with drive unit on a bedplate (pump-set). In either case, any exposed machined parts are
coated with a suitable rust inhibitor.
Each pump is supplied complete with inlet and outlet flanges and gaskets, drive key, and
with the bearing cylinder charged with grease.
The packing or boxing will always be more than adequate for the method of shipment and
subsequent storage.
On receipt of the pump, check that the items listed on the consignment list have been
supplied and have not been damaged in transit. Ensure that the inlet and outlet apertures
are clear and that the impeller runs freely when the shaft is turned by hand.
If the pump has been disassembled for shipment, a consignment list will contain complete
information on the identification of parts. Where parts are boxed, each box is numbered
and the corresponding number is noted on the consignment list.
If damage has occurred or any items are missing, immediately file a report with the carrier
making the delivery. Also, submit a written report to Metso Minerals detailing the damage
and/or missing items, as soon as possible.
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General
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Slurry Pump
1.2.2
Handling and lifting
Whether at the depot or on site, ALWAYS follow normal handling and lifting procedures and
instructions contained or referred to in this manual.
Handling of centrifugal pumps requires great care, especially larger or more cumbersome
items of machinery. All slinging, lifting or conveying MUST be carried out by appropriately
skilled personnel.
Always lift slowly and smoothly, maintaining the pump in a level attitude.
For your covenience and safety, approximate weight of the pump, or pump complete with
drive unit and baseplate, is in the Appendices, Section 11.
WARNINGS
MAKE SURE THAT ALL SLINGS, SHACKLES, ETC. USED ARE OF ADEQUATE LOAD CARRYING CAPACITY
FOR THE UNIT TO BE LIFTED. CHECK THAT ALL LIFTING EQUIPMENT CERTIFICATES ARE CURRENT.
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General
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Slurry Pump
1.2.3
General storage instructions
• Re-apply rust inhibitor to all moving parts, at least, every two months.
Protect pump against dust and weather by storage indoors or under weatherproof cover
Protect pump against impact
WH03AA1AAA0en_03b.doc
Turn shaft at least every month
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General
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Slurry Pump
1.2.4
Long-term field storage
Minimum requirement for storage and maintenance of centrifugal type pumps on site
before their installation and start-up.
1.
Medium term storage
Indoor storage of equipment is recommended in order to prevent the harmful effects of
exposed conditions, particularly in dust laden atmospheres.
The standard anti-rust protection provided prior to dispatch remains adequate for periods
not exceeding two months.
Whenever indoor storage is not possible, it is necessary to follow the guidelines given
below:
a)
Locate the pump set with its bedplate on a concrete floor and supported on
wooden joists of approximately 100 mm x 100 mm in section.
b)
Cover the pump set, whether located indoors or outdoors, with a strong,
waterproof cover extending down to the baseplate. The cover must be securely
fixed to withstand ambient weather conditions.
c)
Prior to fitment of the cover, ensure that:i. all openings, including inlet and outlet apertures, are properly sealed, and;
ii. the bearing cylinder and drive are properly protected against dust.
2.
Prolonged storage -up to 2 years
The following steps are essential in all cases where prolonged storage is foreseen:
a)
The pumps are to be adequately warehoused in a closed dry and, if possible, a
temperature controlled building.
b)
Every six months, the stuffing box/shaft seal sleeve area should be inspected,
cleaned and re-coated with a suitable anti-rust compound, if required.
c)
If disassembly of the pump is not practical then proceed as follows:i. Desiccate the pump case with hot air at 35°C to 65°C.
ii. Seal all pump openings and attach sachets of hygroscopic salts (silica gel).
iii. During the desiccation with hot air, ensure that no other parts become
overheated as this may be detrimental.
d)
The pump rotor should be turned over several times by hand at intervals not
exceeding one month.
e)
The bearing grease should be checked at least once every twelve months.
f)
The bearing cylinder must be disassembled, cleaned and regreased prior to
reassembly at least once every 24 months.
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General
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Slurry Pump
During prolonged storage, it may prove difficult to rotate the pump rotor manually for
normal maintenance. In such cases proceed as follows:a)
Loosen the bearing end covers which limit the axial displacement of the
bearings.
b)
Move the pump rotor along its axis, thus freeing the assembly and allowing
manual rotation.
3.
Storage in excess of two years
For prolonged storage in excess of two years in adverse ambient conditions, special
protection may be necessary. Any moisture absorbing devices used must be absolutely
effective and regularly maintained. Whenever possible for storage periods in excess of two
years, it is recommended that all pump components are disassembled, washed, dried,
protected and reassembled afterwards. This work may be done by Metso Minerals and
charged to the purchaser under normal rates in force at the time the service is carried out.
1.2.5
Storage of spares
In general, unless otherwise instructed, keep all spares parts in a cool, dry environment
and protect rubberised/synthetic components from sunlight and high voltage electrical
equipment.
Rubber is affected by ageing and its rate of deterioration is dependent on the type of
rubber and the storage conditions. Rubber perishes most rapidly when exposed to heat,
ultra violet light and oxidants. The more commonly overlooked sources of which are
sunlight and electrical machinery. Rubber can become permanently deformed if
compressed out of shape during storage. Mineral oils, solvents, dust, contact with metals
and moisture can also damage rubbers depending on type.
Certain types of rubber such as chloroprene rubber (CR) harden at temperatures below
+5°C. In conditions of extreme cold these types of rubber harden to such an extent that
they could develop cracks and be damaged by handling. Chloroprene rubber does not
regain its normal hardness when the ambient temperature rises but has to be
reconditioned.
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General
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Slurry Pump
To ensure rubber products maintain their original properties, storage conditions must be
controlled. Where practicable, ensure rubber products are:
1.
kept sealed in their original packing which should be opaque;
2.
kept away from direct sunlight;
3.
kept away from electrical machinery -e.g. motors and generators;
4.
kept in a cool, dry environment between 15° C to 25° C;
5.
stored away from exhaust fumes;
6.
stored separately from chemicals and fuels;
7.
stored loosely packed;
8.
rotated on a first in - first out basis.
Storage life for different types of rubber stored under recommended conditions are as
indicated in Table 1.2.5-1.
NOTE: AT 15°C THE STORAGE LIFE WILL BE ABOUT DOUBLE AND AT 35 °C ABOUT HALF OF THAT
STATED IN THE TABLE.
Type of rubber
Product ref.
Storage life @ 25°C (years) *
Natural
NR
5
Nitrile
NBR
7
Chloroprene
CR
7
Butyl
IIR
7
Ethylene-propylene
EPDM
10
Chlorosulphonated polyethylene
(Hypalon)
CSM
10
Table 1.2.5-1 Types of rubber and their expected storage life.
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General
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Pump HM100 MHC-D C5
Pump specification
Headline
Description
Order part no:
Complete pump:
Pump type:
Product code:
Pump no:
Frame size:
ATEX GII C3G
26172301000
PDW
HM100 MHC-D C5
2031
26172301001
FR300
Qty
1
Wear parts, quality:
Special design:
HC
Reverse overhead mounted motor base for 25kW motor.
Guard in brass. Double mechanical seal BA063-P.
None pressurized thermosystem from Huhnseal with stand .
Gyrolock kulventiler och rörkopplingar från Hoke Inc i SS316.
Painting:
Norsok M501 / RAL9010
Capacity m³/h:
Total head m:
Pump speed rpm:
Specific gravity kg/l:
Input power kW:
60
34,7
1507
1,3
15,5
Motor:
Special req.:
FOT IEC180-4 440VY 25KW 1770 rpm 60HZ IP56 IM1001/B3
ABB M3KP180MLB4 EExde IIB T4 Atex
Motor supplied by:
Drive supplied by:
Customer, assembled by Metso Minerals(Sala) AB
Metso Minerals(Sala) AB
Motor sheave:
Motor bushing:
Pump sheave:
Pump bushing:
V-belts:
4SPB160
2517D48
4SPB190
2517D60
SPB1700
Instruction:
1 + 1 Norsk/Engelsk with pump + 1 copy on mail to Gunnar K.
26172301000
Edition 1
JAN
06-W28
General
1/1
Slurry Pump
1.4
Customer service
For any inquiry regarding the servicing and repair of Metso Minerals Slurry pumps please
contact the local Metso Minerals Branch. For information on the Metso Minerals Branch
closest to you, contact one of the Metso Minerals Global Sites listed below:
Metso Minerals (Sala) AB
Norrängsgatan 2
Box 302
S-73325 SALA
Sweden
Tel:
Fax:
(+46) 224 374 00
(+46) 224 169 69
Metso Minerals Industries, Inc.
P O Box 340
COLORADO SPRINGS CO 80901
621, South Sierra Madre (80903)
USA
Tel:
Fax:
(+1) 719 471 3443
(+1) 719 471 4469
Metso Minerals (Oslo) A/S
P.O. Box 14, Leirdal
Prof. Birkelandsv. 36 d
N-1008 OSLO
Norway
Tel:
Fax:
(+47) 2290 3500
(+47) 2290 3590 / 2290 3591
Please provide the following information:
1.
model and size of equipment;
2.
serial number;
3.
approximate date of purchase;
4.
details of enquiry, apparent fault etc..
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General
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Slurry Pump
2
DESCRIPTION
2.1
Product and warning signs
2.1.1
Product signs
All product signs attached to the pump are shown below.
Motor weight
Drive weight
Pump weight
Total weight
Figure 2.1.1-1 Weight plate
The weight sign is mounted next to the machine sign. When the pump is supplied without
motor and drive, only the weight of the pump is stamped on the sign. In which case the
total weight is stamped on the sign by the mechanic who fits the motor and drive on the
pump.
Pump delivered without motor
Pump delivered with motor
Space for CE-mark
Pump type
Pump number
Year of manufacture
Figure 2.1.1-2 Machine plate
A machine sign containing information as above is affixed to the pump.
A pump delivered with motor has a machine sign with CE-mark. When the pump is
delivered without motor the CE-mark has to be affixed when the motor is assembled.
The CE-mark is included in the pump delivery.
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Description
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Slurry Pump
2.1.2
Warning and caution signs
This sign, attached to the drive cover, indicates the
direction of rotation of the pump when viewed from the
drive end.
THERE IS RISK OF SERIOUS DAMAGE TO THE PUMP IF IT IS
ALLOWED TO ROTATE IN THE WRONG DIRECTION.
This sign is a hazard warning and is usually
accompanied by text indicating the nature of the hazard.
THERE IS RISK OF SERIOUS INJURY IF THESE WARNING
INSTRUCTIONS ARE NOT OBSERVED.
The guard should always be
fitted when the pump is in
operation.
If the guard is to be removed,
check that the motor is
disconnected from the mains
or that the main switch is
turned off and locked so that
the motor cannot be started
inadvertently.
WARNING
The V-belt guard must always
be mounted during operation
The sign is mounted on the V-belt guard.
The guard must always be
refitted before the pump is
started.
This sign is attached to a direct-drive coupling guard.
Direction of rotation of the pump is indicated by this sign
attached to the front of the case.
This sign, attached to the frame, indicates that the pump
requires periodic greasing.
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Description
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Slurry Pump
2.2
Applications
The Metso Minerals Slurry Pump has been designed for a wide variety of abrasive
pumping duties. While the pumps may be used in many different industries, they are all
designed for constant use in the most arduous conditions. These high-efficiency pumps
are of a simple design, providing ease of maintenance and facilitating replacement of
wearing parts.
2.3
Design
2.3.1
General
Slurry Pumps are made up of four basic modules, the frame (A), the bearing cylinder (B),
the shaft seal (C) and the wet-end (D) assemblies – see Figure 2.3.1-1.
A comprehensive range of modules are available, to configure pumps to suit a wide range
of applications.
Pumps are supplied bareshaft or as fixed-base pumpsets with various choices of motor
mounting position. Manual or hydraulic slide-bases are optional.
Maximum efficiency is maintained by setting impeller running clearance(s). The adjustment
is easily carried out during maintenance and shut-down periods.
Standard bearing cylinders are grease lubricated, but oil lubricated bearings are an option.
Pump designation is made up of letters which identify the range and numbers which
indicate the inlet diameter in millimetres –e.g. HM150.
C
D
B
A
Figure 2.3.1-1 Typical outline design of Metso Minerals Slurry Pumps showing the basic
pump modules: Frame (A), Bearing cylinder(B), Shaft seal(C), Wet-end (D)
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Description
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Slurry Pump
2.3.2
Noise level
In certain installations and outside the optimum operating conditions, the noise level of 70
dB(A) may be exceeded. The motor generates most of the noise and, in general, the
noise level for properly designed installations will be about 2dB(A) above that of the motor.
2.3.3
Vibration
The pumps are in ClassIV as described in ISO10816-1.
When the pump is new, the vibration level at any bearing should not exceed 7.1 mm/s.
Vibration levels above 11 mm/s should always receive attention.
CAUTION
SHOULD VIBRATION LEVELS EXCEED 18 mm/s, STOP THE PUMP IMMEDIATELY.
Common reasons for high vibrations are:
⇒
inadequately tightened fasteners;
⇒
slack V-belt;
⇒
misalignment of the drive;
⇒
the pump impeller is blocked by debris.
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Description
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Slurry Pump
2.4
Materials and maximum working pressures
Metso Minerals Slurry Pumps are constructed from materials selected to give excellent
wear characteristics over the full range of pumping duties. This section lists the materials
of construction and working pressures for STANDARD duty applications.
Other materials are also used for specialist applications or as specified by the customer
– see section 1.3 .
Item
MATERIALS OF CONSTRUCTION
Material Type
Material Code
Material Standard
Case
White Cast Iron
JN3049
EN 12513
Impeller
White Cast Iron
JN3049
EN 12513
Back Liner
White Cast Iron
JN3049
EN 12513
Bearing Frame
Cast Iron
JS1030
EN 1563
Expeller
White Cast Iron
JN3049
EN 12513
Expeller Ring
White Cast Iron
JN3049
EN 12513
Expeller Ring (option)
Cast Iron
JS1030 PU Lined
EN 1563
Stuffing Box
Cast Iron
JS1030
EN 1563
Shaft Sleeve
White Cast Iron
JN3049
EN 12513
Shaft Sleeve (option)
Stainless Steel
1.4401
EN 10088
Shaft Sleeve (option)
Stainless Steel
1.4021
EN 10088
Shaft Sleeve (option)
Stainless Steel
1.4462
EN 10088
Shaft
Steel
1.1191
EN 10083
Seals
Nitrile Rubber
NBR
-
PUMP
WORKING PRESSURES
SIZE
Bar
kPa
HM50
18.6
1860
HM75
18.6
1860
HM100
15.9
1590
HM150
15.6
1560
HM200
15.6
1560
HM250
15.6
1560
HM300
15.6
1560
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Description
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Slurry Pump
2.5
Surface treatment
2.5.1
Standard finish
The external surfaces of the pump are protected by the anti-corrosive system specified in
Table 2.5.1-1, except exposed machined surfaces which are coated with an air drying rust
inhibitor. Drive motors are supplied in the original manufacturer’s standard finish.
Stainless steel, plastic or elastomeric parts are not painted.
Table 2.5.1-1 Paint specification
COATING
TYPE
COLOUR
Finish 70 DFT (µm)
Finish
(all except
guards)
Two-pack gloss
oxiranester thick coat
paint
Blue
(RAL 5009)
Gloss
120
Finish
(guards only)
Epoxy powder
Yellow
(RAL 1032)
Gloss
100
2.5.2
Paint repairs
To repair damage to a painted surface;
1.
remove any trace of oil and dirt using solvent wash;
2.
remove all loose paint by chipping or scraping back until only sound paintwork
remains and clean the exposed surface by wire brushing or other mechanical means
to grade St2 of Swedish Standard SS 055900 (ISO 8501-1:1988);
3.
sand down and feather a 25mm band of the sound bordering paintwork;
4.
vacuum the surface to remove all dust and debris;
5.
apply the paint system specified in Table 2.5.1-1.
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Description
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Pump HM100 C5
Performance curve
Full impeller dia Vane diameter Vane config
300 mm
300 mm
Full
40%
2600 r/min
Impeller type
No. of vanes
Closed
50% 55%
Max sphere
5
Impeller material Liner material
30 mm
Metal
Metal
60%
65%
100
2400
BEL
67%
80 2200
65%
2000
H (m)
60
6,00 m
1800
1600
40
5,00 m
1400
4,00 m
1200
20 1000
3,00 m
800
1,00 m
50
60%
2,00 m
100
150
200
250
Based on clear water tests
correct for other conditions
2600
80
2400
60
2200
P (kW)
2000
40
1800
1600
20
1400
1200
800
50
1000
100
150
200
250
Q (m³/h)
13AAAAHCHCC5
Edition 4
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06-W22
Description
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Slurry Pump
2.8
Certificates and test results
DECLARATION OF CONFORMITY
We, Metso Minerals (Sala) AB, Norrängsgatan 2, 733 25 SALA, SWEDEN declare
that the slurry pump
Manufacturer
Pump type
Pump number
Year of manufacturing
Metso Minerals (Sala) AB
HM100 MHC-D
26172301001
2006
to which this declaration relates is in conformity with the following standards
-
EN 292-1
EN 292-2
EN 809
Safety of machinery – Basic terminology, methodology
Safety of machinery – Technical principles and specifications
Pumps and pump units for liquids - common safety
requirements
EN13463-1 Non-electrical equipment for potentially explosive
atmospheres – Basic method and requirements
EN13463-5 Non-electrical equipment for potentially explosive
atmospheres – Protection by constructional safety
following the provisions of Directive: 98/37/EG
: 94/9/EC
CE marking
European Commission mark for EX-products
Pump type
Equipment group: Surface
Pump number
Equipment category
Year of manufacture
Gas
2004-04-14 in Sala, Sweden
Name:
Position:
100-conformity-en
Jan Andersson
General manager
Slurry pump division
Edition 0
JAN
04-W16
Declaration of conformity
1/1
CERTIFICATE
No. A/06-535612
Rev 00
Date
Page
2006-01-11
1/2
INSPECTION CERTIFICATE acc to
EN 10 204 3.1
Huhnseal AB
Box 288
261 23 LANDSKRONA
Customer References
Sandvik References
Order No. Subs No. ABSMT Dispatch note
123034
58554
39152/53
ABSMT No. C.Code
284-55835 87
Customer
order
2005-12-19
640224
003-00991
HUHNSEAL
Material description
HOT WORKED STAINLESS BAR STEEL
FORGED
ANNEALED & STRAIGHTENED
PEEL TURNED AND POLISHED
Steel/material Designations
Sandvik
SANMAC 316/SANMAC 316L
AISI
UNS
316/316L
S31600/S31603
W.nr
EN no
1.4401/1.4404
1.4401/1.4404
Steel making process
Electric furnace
Technical requirements
EN 10088-3:-2005
NACE MR0175/ISO 15156-3:2003
ASTM A-276-04, A-479-04, ASME SA-479-ED-04 SEC II PART A
EXTENT OF DELIVERY
It Product designation
02 MBR-SANMAC-316L-240
FL-15-22-
TEST RESULTS
Chemical composition (weight%)
Heat
C
Si
Mn
507843
0.013
0.24
1.67
V
N
507843
0.033
0.045
Tensile test at room temperature
Yield strength
N/mm2 N/mm2
Lot
Rp0.2 Rp1.0
11241
244
287
Heat
Lot
Pieces
507843 11241
15
Kg
120.0
Total
120.0
P
0.026
15
S
0.026
Tensile strength
N/mm2
Rm
521
Cr
16.73
Ni
10.18
Elongation
%
%
A
2"
60
60
Mo
2.05
Red.of Area
%
Z
68
Hardness test
Lot
11241
Min
HB
152.0
Max
HB
153.0
Quality assurance - Ulf Svensson/QA-manager Primary Products
MTC Service / Certificates
AB SANDVIK MATERIALS TECHNOLOGY Reg No. 556234-6832 VAT No. SE663000-060901
SE-81181 SANDVIKEN SWEDEN www.smt.sandvik.com mtc_service.smt@sandvik.com
CERTIFICATE
Grain size
Lot
11241
No. A/06-535612
Rev 00
Date
Page
2006-01-11
2/2
4.0
Following controls/tests have been satisfactorily performed:
- Intergranular corrosion test acc to ASTM A-262 PR.E
- Material Identification.
- Visual inspection and dimensional control.
Heat Treatment:
Solution annealed and quenched.
Intergranular corrosion test acc to EN ISO 3651-2 Method A.
Material free from mercury contamination.
No welding or weld repair.
This is to certify that the contents of this certified material test
report are correct and accurate and that all test results and
operations are in compliance with the material specification.
This material complies fully with the chemical analysis and mechanical
properties of ASTM A-182 and ASME SA-182 Grade F316L
The material is manufactured according to a Quality system,
approved and registered to ISO 9001.
The certificate is produced with EDP and valid without signature.
AB SANDVIK MATERIALS TECHNOLOGY Reg No. 556234-6832 VAT No. SE663000-060901
SE-81181 SANDVIKEN SWEDEN www.smt.sandvik.com mtc_service.smt@sandvik.com
Certificate of compliance
Certificate number
Customer name
0508
Metso Minerals
The certificate is issued to certify that the material we supply to Metso for components in the
“Denver Orion range”, PD731047, PDCH2012, PD771010, PD741041, complies with the following
specification :
MIS
NO
MITAK
Closest
Metso
C
Si
(max)
Mn
P
(max)
S
(max)
Cr
Ni
(max)
Mo
(max)
Cu
(max)
Bhn
(min)
2.4 to
2.8
1% max
0.5
to
1.0
0.06
max
0.06max
23.0
to
27.0
1%
max
0.5
max
1%
max
600
NO.
1001
ENJN3049
For and on behalf of MIS Engineering (PTY) Ltd
Goosen Dhladla
Quality manager
13 Mars 2006
Slurry Pump
3
HEALTH AND SAFETY
3.1
General
HEALTH AND SAFETY STATEMENT
DO TAKE TIME TO ENSURE THAT YOUR SAFETY AND THAT OF OTHERS IS NOT PUT AT RISK. FAILURE
TO OBSERVE CERTAIN ELEMENTARY SAFETY PRECAUTIONS MAY RESULT IN PERSONAL INJURY OR
DAMAGE TO THIS PUMP EQUIPMENT. THE SAFETY INFORMATION IN THIS AND OTHER SECTIONS IS
INTENDED TO ENCOURAGE A SAFETY CONSCIOUS APPROACH TO OPERATING AND CARRYING OUT
MAINTENANCE.
3.1.1
Warnings and cautions
For the purpose of definition in this manual, a WARNING gives information which if ignored
could lead to serious injury of personnel. A CAUTION gives infomation which if ignored
could lead to serious damage to the pump or associated equipment.
WARNING
PARAGRAPHS WHICH PURELY PROVIDE A WARNING NOTICE ARE BOXED AND HIGHLIGHTED IN THIS
STYLE.
CAUTION
PARAGRAPHS WHICH PURELY PROVIDE A CAUTIONARY NOTICE ARE BOXED AND HIGHLIGHTED IN
THIS STYLE.
3.1.2
Training
It is strongly recommended that all customers' production and maintenance personnel and
site visitors are made fully aware of potential dangers of this equipment. If any doubt
exists, please contact Metso Minerals for advice.
FOR YOUR OWN PERSONAL SAFETY , READ AND TAKE NOTE OF THE FOLLOWING:
HAZARDOUS AREAS
WH14AAAAAA0EN_04D.DOC
- These are in the areas of the impeller, shaft seal,
impeller release mechanism, drive motor shaft,
direct drive coupling or drive belts. Under normal
operating conditions these areas MUST be enclosed
by safety covers or guards. Pump intake and
discharge ports, when open, are also hazardous
areas. NEVER insert your hand into either of these
ports without first ensuring that the pump drive has
been isolated.
JAN
04-W08
Health & safety
1/2
Slurry Pump
LIFTING THE PUMP
-
Make sure that ALL slings, shackles, etc. are of
adequate load carrying capacity. Metso Minerals
Slurry pumps may be provided with lifting eyes
designed for lifting individual components. These
should NOT be used to lift the pump unit or the pump
set. Individual pumps should ALWAYS be lifted by
using slings passed through the bearing frame. See
sub-section 1.2.2 for recommended lifting
techniques.
OPERATING THE PUMP
-
Ensure that ALL safety covers and guards are in
position and securely fitted.
wear loose clothing when working in close
proximity to rotating parts.
DO NOT
allow water or slurry to rise above the top of
the pump base.
NEVER
MAINTAINING THE PUMP
3.2
-
and ISOLATE the electrical supply to the
pump motor and allow rotating parts to come to rest
before carrying out any maintenance or
adjustments.
SWITCH OFF
Warning and caution signs
See sub-section 2.1.
WH14AAAAAA0EN_04D.DOC
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04-W08
Health & safety
2/2
Slurry Pump
4
DESCRIPTION OF OPERATION
4.1
General
Centrifugal pumps work best with minimum wear and other mechanical stress if the
operating point is close to the pump's best efficiency point (BEP). To choose a pump that
works close to its best efficiency line (BEL), it is important to understand how the pump
interacts with the piping system in which it is installed.
In simple terms, a pump and its piping system act as two communicating vessels. The
piping sysem has a resistance curve that starts at the static delivery head, at zero flow. As
the flow increases, the resistance increases with pipe friction. A radial centrifugal pump
has a descending discharge/flow curve for each rpm. The pump's operating point (DP) at a
given pump speed is the point of intersection between the piping system's resistance
curve and the pump's discharge/flow curve. See diagram below.
It is therefore important to calculate the piping
system's resistance curve correctly and to take into
account the manner in which the admixture of solid
particles, for example, affects the curves of the piping
system and pump. We recommend using
Pumpdim™ for Windows™ for our pump
applications.
H
DP
To obtain the best wear properties the pump can be
provided with different materials in the parts exposed
to the greatest wear.
Q
4.2
Best efficiency point
Pressure conditions in the pump casing are shown in Figure 4.2-1. At the BEP there is
even pressure round the impeller, resulting in small radial forces which in their turn exert
little load on bearings and cause little shaft deflection. When the pump operates at low
capacity and not at BEP, differential pressure builds up over the casing volute. This gives
rise to a radial force F on the impeller which is a function of the differential pressure (Pa)
and the impeller's projected area (mm2).
WH14AAAAAA0EN_04D.DOC
JAN
04-W08
Desccription of operation
1/4
Slurry Pump
F
F
BEP
Q
When the pump operates at
best efficiency point, uniform
pressure is obtained in the
casing which in its turn
eliminates radial forces on
the impeller.
When the pump's flow
capacity is not utilized,
uniform pressure in the
pump casing will not be
obtained and this results in
a radial force F on the
impeller.
The magnitude of the radial
force F is greatest when the
pump runs against closed
valve = 0 flow. The force
subsequently diminishes up
to BEP where it is close to
zero. At flows above BEP the
force changes direction.
Figure 4.2-1 Best efficiency point
When the pump is not operating at BEP the bearings will have a shorter service life on
account of shaft deflection. In addition, the differential pressure over the impeller gives rise
to the transport of slurry between the impeller and the inlet liner, causing rapid wear of the
liner.
4.3
Hydraulic effects of operation at, and outside, BEP
Impeller vane inlet
Pump casing nose
1
2
Figure 4.3-1 Operating at best efficiency point
1. The slurry's inflow angle coincides with the impeller's vane angle and no erosive
vortices occur.
2. The slurry's flow angle harmonizes with the angle of the pump casing nose and no
erosive vortices occur.
WH14AAAAAA0EN_04D.DOC
JAN
04-W08
Desccription of operation
2/4
Slurry Pump
The way in which the hydraulic work is affected when the pump does not operate at BEP is
shown in Figure 4.3-2 and Figure 4.3-3 This is of decisive importance in slurry pumping.
Impeller vane inlet
Pump casing nose
3
5
4
6
Figure 4.3-2 Operating outside BEP - At low load
3.
4.
5.
6.
Abrasion on the impeller vane's discharge side.
Vortices occur on the vane's vacuum side.
Vortices.
Abrasion caused by particles striking and bouncing against the surface.
Impeller vane inlet
Pump casing nose
7
9
8
10
Figure 4.3-3 Operating outside BEP - On overloading
7. Vortices are formed on the discharge side of the impeller vane.
8. Abrasion occurs on the vacuum side of the vane tip.
9. Vortices.
10. Abrasion on the pump casing nose.
WH14AAAAAA0EN_04D.DOC
JAN
04-W08
Desccription of operation
3/4
Slurry Pump
Hydraulic efficiency is a function of hydraulic turbulence - the more turbulence, the less
efficiency. In slurry pumping, a high level of efficiency is therefore important.
Little hydraulic turbulence is formed at BEP and the abrasion is chiefly of a sliding nature,
since the differential pressure is low when the slurry passes through the impeller and
pump casing. The rate of abrasion is low and the wear is spread evenly over the surfaces.
The rasping wear or high-pressure wear that occurs between the impeller and suction side
liner is lower, since the evenly distributed hydraulic pressure reduces recirculation.
When the full capacity of the pump is not used and its efficiency is less than at BEP,
hydraulic turbulence occurs and the solid particles in the slurry strike and rasp the impeller
and pump casing. This causes local wear damage and the service life of these
components is severely shortened. At the inlet to the impeller the slurry's flow angle is not
the same as the pump vane angle, which gives rise to turbulence and results in
recirculation of slurry in the channel. At the pump casing nose the flow from the impeller
does not harmonize with the shape of the casing, causing turbulence to occur immediately
after the pump casing nose.
In the worst case, oversized pumps which do not operate at BEP result in bearing
breakdown, shaft fracture and unevenly worn inlet and pump casing liners with deep wear
marks at the casing nose.
4.4
Choice of pump size
For preference, choose the pump size which operates as close as possible to the pump's
best efficiency point (BEP).
WH14AAAAAA0EN_04D.DOC
JAN
04-W08
Desccription of operation
4/4
Slurry Pump
5
CONTROL SYSTEM
(NOT APPLICABLE)
WH14AAAAAA0EN_04D.DOC
JAN
04-W08
Control system
1/1
Slurry Pump
6
INSTALLATION
6.1
General
Refer to sub-section 1.2 for handling instructions.
6.2
Foundation requirements
Ideally, the pump and its drive should be mounted on a common bedplate which is fixed to
a level foundation of adequate strength. All bedplates supplied by Metso Minerals
incorporate holding-down bolt holes. It is recommended that the pump is installed in such
a way that maintenance and adjustments can be carried out easily. It is essential that the
pump is not subjected to flooding.
A foundation must provide a rigid and durable support, while absorbing shock loads and
vibrations to and from the machine. Many criteria influence its design, its construction
materials and its preparation: vibration and loading characteristics, operating environment
and effect of nearby machinery are some. Each installation is, therefore, a special case
needing careful examination of its particular requirements. The following are general
guidelines for preparing a foundation for Metso Slurry Pumps –refer to Figure 6.2-1 for
details.
Mv
A1
Ed
Ed > (12×ØD)
C min > 1.25 × B min
A2
A3
A4
< 1
240
A min
B min
C min
ØD
Figure 6.2-1 Foundation and fixings, general arrangement
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
1/8
Slurry Pump
1.
The foundation must be poured on a well prepared solid ground.
2.
A mixture of good quality cement and coarse aggregate is suitable in most cases,
but, where applicable, the chemistry of the soil and the operating environment may
impose additional requirements. Reinforcement bars may also be necessary
depending on application.
3.
The total foundation mass and its related support structures should be at least five
times the total weight of the rotating assembly. The weight of the rotating assembly
– excluding the rotating parts of the motor – is roughly ¼ of the weight of the bare
shaft pump. See section 11.3 for the bareshaft assembly weight.
4.
Foundation depth (Cmin) should be at least 125% of the anchor hole depth (Bmin).
5.
For maximum strength, anchor fixings should be positioned more that 12 times the
anchor hole diameter (ØD) from the edge of the concrete slab (Ed).
6.
The concrete slab should be level to within 12.5 mm in 3000 mm.
7.
If the installation is in close vicinity of other moving machinery, then necessary
precautions should be taken to prevent cross-talk.
6.3
Installation tools and equipment
Apart from suitable lifting equipment, a standard fitter's tool kit together with suitably-sized
hexagon key wrenches and torque wrenches are normally sufficient to install the pump.
See Toolkit, sub-section 10.6.
Metso Minerals can supply all recommended fixtures and tools at additional cost.
WH15AM1AAA0EN_07A.DOC
JAN
05-W02
Installation
2/8
Slurry Pump
6.4
Installation procedure
6.4.1
Pump
When the foundation has fully cured, the anchor bolts may be installed –refer to Figure
6.2-1 and Figure 6.4-1.
a)
Spacing between anchor fixings should normally be more than 10 times their
diameter, unless otherwise instructed. Refer to manufacturer’s instructions for
specific details.
b) Lift the pumpset into position over the foundation and align it as required in the plant
layout drawing.
NOTE: IF LIFTING THE PUMPSET INTO POSITION IS NOT CONVENIENT, PREPARE A FOOTPRINT
PATTERN OF THE BEDPLATE (A3) USING HARDBOARD.
1
3
2
4
Figure 6.4-1 Installing the anchor fixings
1.
With the pumpset (or the pattern) in position, drill the required number of holes in the
foundation.
NOTE: ENSURE THAT THE HOLE DEPTH (B MIN) AND DIAMETER (ØD) CONFORM TO THE BOLT
MANUFACTURER’S SPECIFICATION.
2.
Blow out the dust and debris from the holes.
3.
With the pumpset in position, level the bedplate using shims (A4), if necessary, and
tap in the anchor fixings to a depth (Amin), as specified by the bolt manufacturer.
4.
Assemble the fixing nuts to the anchor fixings and tighten to the torque setting (Mv),
as specified by the bolt manufacurer.
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
3/8
Slurry Pump
6.4.2
Belt driven pumps
1.
Make allowances for possible pump shaft forward adjustment when positioning the
drive pulley on the shaft.
2.
Align the pump and motor pulleys correctly. Misalignment between pulleys could
cause excessive belt wear, heat generation and noise.
6.4.3
Direct driven pumps
Where practicable, fit a spacer coupling so that the pump "back pull-out" method can be
used, thus avoiding the need to remove the drive or other equipment. The minimum
distance between shaft ends needed to facilitate the "back pull-out" method is given in,
‘General Arrangement’, sub-section 2.6.
NOTE: ALWAYS CHECK DRIVE ALIGNMENT AFTER INSTALLATION.
6.4.4
1.
General installation procedure
Check that the inlet and outlet openings and the case are clear of any debris and that
the respective joint seals are in position before connecting the pipework.
WARNING
WHERE THE SYSTEM IN WHICH THE PUMP IS INSTALLED IS DESIGNED IN SUCH A WAY THAT THE PUMP
INLET AND OUTLET LINES CAN BE SHUT OFF OR COULD BECOME BLOCKED SIMULTANEOUSLY, SET
THE SAFETY VALVE TO THE PRESSURE SPECIFIED IN ‘MATERIALS AND MAXIMUM WORKING
PRESSURES’, SECTION 2.4. THIS IS DESIGNED TO ELIMINATE THE RISK OF THE PUMP BURSTING,
WHICH COULD HAPPEN IF THE PUMP IS RUNNING WITH BOTH THE INLET AND OUTLET LINES SHUT
OFF.
2.
DO NOT force the pipes into alignment with the inlet and outlet joint flanges. Avoid
unnecessary loads on the pump by ensuring that all pipework is adequately
supported and is not resting on the pump. See table 6.5.1
NOTE: THE JOINT FLANGES ARE SPLIT FOR EASE OF ASSEMBLY. IF FOUND TO BE LOOSE, TIGHTEN
THE RESPECTIVE SCREWS TO THE TORQUE LOADING NOTED IN THE TORQUE TABLE, SUBSECTION 11.1.
3.
Disconnect the drive belts or coupling before connecting the electrical supply to the
drive motor.
4.
Run the motor and check that it turns in the direction indicated by the arrow sign –
see section 2.1.2.
CAUTION
THE PUMP MUST NOT BE RUN IN THE OPPOSITE DIRECTION AS THIS COULD RESULT IN THE IMPELLER
UNWINDING FROM THE SHAFT, CAUSING EXTENSIVE DAMAGE TO THE PUMP.
5.
Reconnect the drive belts or couplings as necessary.
6.
Re-check drive component alignments, and re-set if necessary –see section 9.5.6 .
NOTE: ALWAYS CHECK DRIVE ALIGNMENT AFTER INSTALLATION.
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
4/8
Slurry Pump
7.
Connect the gland water supply pipe, in case of pumps with a water flush gland seal.
Water must be clean, and at the correct pressure and flow rate. See Table 6.4.4-1
and section 9.5.3.
Recommended water quality for flushed gland
pH
:
6.5 to 8
Dissolved solids
:
< 1000 PPM
Suspended solids
:
< 100 PPM
Max particle size
:
- 60µ
Max individual dissolved ions
:
Hardness (Ca+, Mg+)
:
< 10º dH
Calcium Carbonate (CaCO3)
:
< 20 PPM
Sulphate (SO4-)
:
< 50 PPM
Table 6.4.4-1 Recommended water quality for flush water
8.
Ensure that all safety covers are fixed securely in position.
NOTE: IF THE PUMP HAS BEEN BROUGHT OUT OF STORAGE, LUBRICANT RENEWAL MAY BE
ADVISABLE. SEE LONG TERM STORAGE RECOMMENDATIONS IN SECTION 1.2.4 .
6.4.5
Cold climates
Where there is the likelihood of pump being exposed to below freezing conditions the
following precautions are strongly recommended.
1.
If practical, on site all pumps should be installed with their outlets in position-3 as
shown in ‘General Arrangement’, sub-section 2.6.
2.
Immediately pump is stopped drain discharge pipework.
3.
Where practicable, fix adequate drain plugs on discharge pipework local to pump.
4.
Disconnect flange fixings to pump oulet and inlet. Siphon out as much of the slurry
as possible.
A small amount of slurry can remain in bottom of pump case provided it does not come in
contact with the impeller.
These precautions will make it possible to drain the pump and its pipework of all slurry
during shut-downs.
6.4.6
Pump outlet positions
To reposition the pump case outlet to suit existing pipework, follow relevant instructions in
Dismantling and Assembly, section 9.5. ‘General Arrangement’, sub-section 2.6 shows
the possible outlet positions.
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
5/8
Slurry Pump
6.5
Pipe connections and pump sump
CAUTION
DO NOT INSTALL THE PIPEWORK IN SUCH A WAY THAT IT PUTS ANY EXCESSIVE LOAD ONTO THE
PUMP CASE. TABLE 6.5-1 INDICATES THE STANDARD ALLOWABLE FLANGE FORCES. PLEASE
CONSULT METSO MINERALS SHOULD THE FLANGE LOAD REQUIREMENT BE GREATER.
Fy
My
CL
Fz
Mz
Mx
Fx
FLANGE SIZE
FX AND FY (N)
FZ (N)
MX AND MY (Nm)
Mz (Nm)
32
350
700
165
325
50
510
1000
240
475
80
800
1600
370
750
100
1100
2200
510
1000
150
2000
4000
895
1790
200
2900
5800
1325
2650
250
4350
8700
2000
4000
300
5800
11600
2650
5300
350
7600
15200
3500
6900
400
9700
19400
4500
8900
Table 6.5-1 Allowable flange forces
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
6/8
Slurry Pump
Q(m3/s)
15s < V/Q < 2min
(4 × D) < L < (10 × D)
h
L
3
V(m )
H
D
S
F
45º-60º
d
Figure 6.5-1 Recommendations for pipework layout
The pump is NOT self-priming, which means that the pump case must be full of liquid
before the pump is started. Additionally, take note of the following (see also Figure 6.5-1):
•
Sump bottom should have an angle of 45º. Fast settling particles may require up to
60º.
• Sump feed (h) should be below the sump liquid surface to avoid air entrainment.
Allowing the pump to draw air will drastically reduce the useful life of the hydraulic
parts.
• Sump volume should be as small as possible. Slurry ‘Retention Time’ is the relevant
parameter for determining the size of the sump. It ranges between 15 seconds and 2
minutes for slurries containing coarse particles and fine particles, respectively.
• Separate sumps are preferred for standby pump installations. This will avoid settling
out in the standby pump when not in use.
• For slurry applications, ensure a steady, uniform feed to the pump, where practicable.
• Install the pump as close as possible to the sump.
• Keep the length of suction pipe and the number of bends in the pipework to the
minimum practicable. Use reinforced flexi-pipes (F) to connect to inlet and outlet.
NOTE: INLET PIPE SHOULD, HOWEVER, HAVE A STRAIGHT LENGTH (L), AT LEAST, 4 TIMES ITS
DIAMETER TO ENSURE FAVOURABLE FLOW CONDITIONS INTO THE PUMP. IF A VALVE (S) IS
FITTED ON THE INLET SIDE, IT MUST BE FULLY OPEN WHEN THE PUMP IS RUNNING AND
SHOULD HAVE A STRAIGHT FLOW PATH OF THE SAME AREA AS THE CONNECTED PIPE.
SUCTION PIPES WHICH ARE LONGER THAN 10 TIMES THE DIAMETER SHOULD BE AVOIDED.
•
•
Sump level (H) should be 6 times pump inlet diameter (D) when measured from the
centre line of pump.
The diameter of the inlet pipe should be the same as, or larger than, the pump inlet
diameter.
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
7/8
Slurry Pump
•
•
•
6.6
A drain valve should be incorporated in the inlet pipe. A floor channel should also be
provided directly beneath it for recovering the waste slurry.
Secure the pump inlet and outlet pipes separately to avoid unnecessary transmission
of vibrations, forces or moments to the pump.
Use expansion joints for high-pressure applications.
Shaft gland
See Care and Maintenance, Section 9, for specific installation instructions.
6.7
Motor and drive
See Care and Maintenance, Section 9, for specific installation instructions.
WH15AM1AAA0EN_07A.DOC
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05-W02
Installation
8/8
Slurry Pump
7
COMMISSIONING
WARNING
BEFORE CARRYING OUT THE FOLLOWING CHECKS, ISOLATE THE ELECTRICAL SUPPLY TO THE
MOTOR.
1.
If the pipework has not been connected to the pump on installation, ensure that the
pump case and associated pipework are clear of any construction debris, slurry etc.
before connection.
2.
Ensure that the foundation and the securing bolts are tight.
3.
Check that the rotating assembly is free to turn manually.
4.
Check that the direction of rotation is correct -see General installation procedure,
section 6.4.4.
CAUTION
THE PUMP MUST NOT BE RUN IN THE OPPOSITE DIRECTION AS THIS COULD RESULT IN THE IMPELLER
UNWINDING FROM THE SHAFT, CAUSING EXTENSIVE DAMAGE TO THE PUMP.
5.
Check lubrication.
NOTE: THE BEARINGS AND SEAL ASSEMBLIES ARE GREASE PACKED ON ASSEMBLY. SEE
LUBRICATION, SUB-SECTION 9.4.
6.
Ensure that the openings on each side of the bearing frame and the area around the
gland are clear of debris, dried slurry, etc.
7.
Check that all safety guards are secured in position.
WH15AM1AAA0EN_07A.DOC
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04-W51
Commissioning
1/1
Slurry Pump
8
OPERATING INSTRUCTIONS
8.1
Start-up
1.
If the pump has just been maintained or has not been put into operation for some
time, then carry out the pre-start checks as described in Commissioning, section 7.
2.
Open the pump inlet and outlet valves.
3.
Check for leakage from the inlet and outlet connections.
NOTE: AN INLET-SIDE LEAK MAY CAUSE THE PUMP TO DRAW AIR DURING OPERATION, THUS
DRASTICALLY REDUCING ITS PUMPING CAPACITY.
4.
If a water flushed gland is fitted, ensure that the water supply is turned on, and water
is available at the correct pressure and flow rate.
5.
If a mechanical seal is fitted, see section 9.5.3 before start up.
6.
If auxiliary priming equipment is fitted, start the priming pump.
7.
Start the pump drive motor.
8.2
Shutting down
The appropriate shutdown procedure for any installation depends on the slurry being
pumped, and more generally on the process requirements upstream and downstream of
the pump. What follows, therefore, may only be regarded as general guidelines for
ensuring some degree of protection for the pump without reference to the particular
application.
•
•
Where practicable, switch the pump to clean water and allow the pipeline to be flushed
through before shutting down.
In case of systems with substantial discharge pipework and/or head of slurry, means of
isolating the pump or draining the system should be provided –see section 6.5.
CAUTION
STOPPING THE PUMP WHEN THERE IS A HEAD OF SLURRY IN THE DISCHARGE PIPE SHOULD BE
AVOIDED AS THIS COULD RESULT IN DAMAGE TO THE GLAND AND/OR PUMP.
•
Having shut down the pump on clean water, close its isolating valves and then drain
the pump and its pipework, if required.
CAUTION
ALWAYS CLOSE THE OUTLET VALVE FIRST. NEVER CLOSE THE INLET VALVE WHILE THE PUMP IS
RUNNING.
NOTE: REVERSE FLOW, IN ADDITION TO POSING A RISK OF DAMAGE TO THE SHAFT SEAL, CAN ALSO
CAUSE THE IMPELLER TO SPIN IN THE REVERSE DIRECTION. STARTING THE PUMP UNDER
THESE CONDITIONS MIGHT CAUSE DAMAGE TO A MECHANICAL SEAL, IF FITTED, AND/OR CAN
IN EXTREME CASES CAUSE THE SHAFT TO SHEAR. AN OVERRIDE CIRCUIT IS RECOMMENDED
TO PREVENT THE PUMP BEING STARTED INADVERTENTLY WHILE THE IMPELLER IS ROTATING.
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•
For short stoppage periods ONLY and where there is NO risk of the slurry settling out, or
solidifying in the system:
Pumps with expeller seal -
immediately after shutting down, close the
isolation valves and then drain the pump
and the sump, if necessary.
Pumps with water flushed gland or
mechanical seal
leave the flush water ‘ON’ when shutting
down the pump, then close the isolation
valves and finally drain the pump and the
sump, if necessary.
Where there is a risk of slurry settling out, or solidifying, refer to the plant operation manual
for the appropriate shutdown procedure.
CAUTIONS
FORMATION OF ICE CAN BLOCK OR BURST THE PIPEWORK AND THE PUMP CASE. IN BELOW
FREEZING CONDITIONS, ENSURE THAT THE PUMP CASE, AND PUMP INLET AND OUTLET PIPEWORK IS
DRAINED OF ALL SLURRY FOR ANY LENGTHY SHUT-DOWN.
8.3
Running checks
During pump operation, the following checks should be made:
1.
Check for leakage from the inlet and outlet connections, and from the gland seal.
NOTE: AN UNTIGHT INLET FLANGE MAY NOT BE EASILY NOTICEABLE DURING OPERATION, AS THE
PUMP COULD BE DRAWING AIR. CHECK FOR INLET-SIDE LEAKS BEFORE START-UP.
2.
Check for excessive noise and vibration -see Description, section 2.
3.
Check bearing temperature and lubrication –see Lubrication, sub-section 9.4.
4.
Periodically verify that the shaft seal is correctly adjusted. If a water flush gland seal
is fitted, ensure that the water supply is at the correct pressure and flow rate. (Refer
to section 9.5.3 for shaft seal setting details.)
5.
Check that the pump performance is satisfactory. (See Capacity Curves, section 2.7)
NOTE: IF THE RUNNING CHECKS ARE UNSATISFACTORY, PUMP ADJUSTMENT OR MAINTENANCE MAY
BE REQUIRED.
IMPORTANT NOTE: AFTER THE FIRST 100 HOURS OF OPERATION, CHECK AND ADJUST THE IMPELLER
AXIAL CLEARANCE. SEE SECTION 9.5.1.
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9
CARE AND MAINTENANCE
9.1
Safety measures
WARNINGS
ISOLATE THE PUMP FROM ALL SOURCES OF ELECTRICITY AND POWER, BEFORE COMMENCING ANY
MAINTENANCE WORK.
ALWAYS ASCERTAIN THE NATURE OF THE PROCESS LIQUID BEFORE COMMENCING WORK ON A
PUMP AND FOLLOW THE HEALTH AND SAFETY PROCEDURES RELEVANT TO THE PROCESS LIQUID. IT
MAY BE HARMFUL TO HEALTH.
Should the process liquid be of a harmful or hazardous nature take the following
precautions as a minimum;
1.
always use protective goggles and rubber gloves;
2.
flush the pump thoroughly with clean water, before opening the pump;
3.
after removing the components, flush them thoroughly with clean water.
4.
follow the health and safety instructions provided in section 3.
9.2
Preventive maintenance & service schedule
9.2.1
Routine maintenance
Use the maintenance schedule below as a basis from which to produce a schedule
suitable to each pumping application after experience in operation has been gained.
WARNING
BEFORE CARRYING OUT ANY MAINTENANCE ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE
MOTOR AND ASSOCIATED EQUIPMENT ARE SWITCHED OFF AND ISOLATED. LOCK IN THE OFF
POSITION OR ATTACH SUITABLE WARNING PLATES TO THE RELEVANT SWITCHES.
ITEM
RUNNING HOURS
ACTION
10
100
Pump Case, Bearing Cylinder
Housing and Gland Area
Pipework
Keep all areas clean and free
from debris, slurry etc.
Hydraulic cylinders (where
applicable)
Check for oil leaks. Rectify, as
required.
Inlet/Outlet Connections
Check for security and leaks.
Rectify as required.
×
Gland Seal - General
Check for leaks. Tighten gland
follower screws or renew seal as
necessary.
×
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250
1000
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ITEM
RUNNING HOURS
ACTION
10
100
Water flushing gland seal.
Check stuffing box connection for
leaks. Rectify as necessary.
×
Centrifugal Gland Seal
Tighten gland follower screws or
renew seal as necessary.
×
Bearing Cylinder
250
Lubricate bearings. See section
9.4.
×
Check Bearings for overheating.
×
All fixings
Ensure attachments are secure.
Tighten to correct torque as
necessary.
Adjusting Screw Locknut (P38)
See Torque Table, Section 11.1.
×
×
Inspect Drive Belts, if fitted, for
deterioration and damage.
Replace as necessary. Check
drive belt tension and adjust as
necessary.
×
×
Check drive couplings, if fitted, for
security of connection.
Pump/Drive unit installation
×
Check safety covers for security
of attachment - important
×
Check drive motor holding down
bolts for security of attachment.
Keep drive motor clean and free
from debris, slurry etc.
Pump impeller
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1000
×
Service Drive Motor as
necessary.
In accordance with
manufacturer’s
instructions.
Check axial clearance after run-in
period. Adjust clearance by
shimming. Refer to Setting Pump
Clearances, sub-section 9.5.1.
After first 100
running hours and
repeat at intervals
equal to 25% of the
anticipated life of
the pump.
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9.2.2
Maintenance recommendations
Metso Minerals recommends that the following actions are carried out prior to any
maintenance:
• clean down the pump, removing any accumulation of debris and/or slurry;
• ensure that inlet and outlet pipeline valves, if fitted, are closed;
WARNING
BEFORE OPENING UP THE PUMP, MAKE SURE THAT ANY LIQUID PRESSURE HAS BEEN RELEASED.
• on breaking a joint face, keep the gasket and ensure it is replaced on assembly;
• if using lifting gear to remove components, ensure that it is of adequate capacity and
that test certificates are valid;
• on larger size pumps it is recommended that special tools are used to help assembly or
maintenance.
For information regarding special tools please refer to Special Tools, section 9.3.
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9.3
Tools and special equipment for service and maintenance
NOTE: THE FOLLOWING SPECIAL TOOLS ARE AVAILABLE FOR PUMPS WITH EITHER SINGLE, OR
DOUBLE, ADJUSTMENT FRAMES.
1.
A special crank-handle to fit over the drive-shaft end diameter and locate the drive
key is advantageous when fitting the impeller to the shaft. See Dismantling and
Fitting the Hydraulic Parts, section 9.5.2.
Figure 9.3-1 Special crank handle
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2.
Two proprietary packing extractors to facilitate the removal of the packing will also be
advantageous.
Figure 9.3-2 Packing extractor
3.
Back-liners for large pumps are very heavy. Specially designed back-liner lifting tools
allow safe handling of the components.
Figure 9.3-3 Back-liner lifting tool for metal pumps
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4.
Shaft seals for large pumps are also quite heavy. A special shaft extension (E)
facilitates removal and refitting of the seal assembly. The tool is also useful for
removing the bearing assembly.
E
Figure 9.3-4 Shaft extension tool
5.
A soft sling (strop) of appropriate lifting capacity (See Approximate Weights Table,
section 11.3) to lift the case assembly is required.
CAUTION
TO PREVENT DAMAGE, ONLY USE A SOFT SLING (STROP) TO LIFT THE CASE.
All of the above special tools can be obtained from Metso Minerals. See section 10.6.
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9.4
Lubrication
9.4.1
First-fill and re-packing after major servicing
Metso Minerals Slurry pumps are lubricated with SKF LGMT3 before dispatch. When
renewing or re-fitting the bearings, they must again be re-packed with grease of the same
specification as detailed in Table 9.4.1-1. The required quantity for each bearing is
specified in Table 9.4.1-2.
Characteristic
Specification
Thickening agent :
Lithium soap
Base oil viscosity at 40 °C :
120 cST
Base oil type :
Mineral oil
Consistency NLGI :
3
Table 9.4.1-1 Grease specification
Frame size
Grease quantity (g)
FR250
75
FR300
100
FR400
125
FR500
325
FR600
500
FR750
625
Table 9.4.1-2 Bearing lubrication - First fill & re-packing
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9.4.2
Lubrication interval
The bearings may be re-greased with any lithium-based grease that conforms to the
specification detailed in Table 9.4.1-1.
The lubrication interval depends upon the shaft speed and the bearing operating
temperature, as shown in Table 9.4.2-1.
Frame Grease
Size
(g)
FR250
20
FR300
25
FR400
35
500
2275
800
1500
Pump speed (rpm)
1000
1500
2000
1000
650
500
1600
1250
1300
1000
900
750
600
500
400
350
300
-
200
-
2500
350
3000
250
FR500
FR600
50
70
1250
1250
900
800
550
350
350
200
-
-
-
FR750
90
900
550
200
-
-
-
-
Table 9.4.2-1 Recommended lubrication interval for bearings @ 70°C (hours)
The pump should initially be re-greased after 250 running hours or the recommended
interval (whichever is less), unless stored for longer than 12 months before start-up, in
which case the long-term storage instructions should be followed (See section 1.2).
Multiply above lubrication intervals by the factors given below if the normal bearing
operating temperature (measured on the rim of the bearing end cover) differs from 70 °C.
Temperature (°C)
Multiplier
50
2.5
60
1.6
70
1.0
80
0.65
90
0.40
100
0.25
110
0.15
120
0.10
While the bearings and specified grease have a maximum operating temperature of
120°C, it is recommended that temperatures above 100 °C be avoided. However,
transient temperatures between 100 °C and 120 °C are acceptable immediately following
re-greasing.
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9.4.3
Lubrication points
The pumps have two bearing lubrication points. See Figure 9.4.3-1.
Part
Bearing cylinder
Position Qty.(cc)
See
A
Table
9.4.2-1.
Motor and/or
gearbox (where
applicable)
–
–
Frequency Lubricant
See Table SKF LGMT3 or equivalent 9.4.2-1.
see Table 9.4.1-1.
–
See manufacturer’s instruction
manual.
A
Figure 9.4.3-1 Lubrication point diagram- Bearing greasing points (A)
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9.5
Dismantling and assembly
9.5.1
Setting pump clearances
•
Impeller clearance adjustment (Standard Slurry Impeller)
These adjustments enable the back (frame side) and front (inlet side) running clearances
to be kept to a minimum so that maximum operating efficiency is maintained throughout
the wear life of the pump. The back impeller clearance is adjusted using the adjusting
screw and the front clearance by adding or removing case shims.
When no further adjustment is possible, the pump must be disassembled and inspected
and worn parts renewed.
1.
Isolate the drive motor and attach suitable warning plates to the relevant switches. It
is advisable to remove the fuses and/or lock the isolator open to avoid accidental
starting.
2.
Remove the drive safety guard and disconnect the belt drive or direct coupling as
applicable.
3.
Where fitted, a mechanical seal requires setting for disassembly. Section 9.5.3
would provide the relevant instructions, where applicable.
4.
Back (Frame Side) Clearance
This clearance, which should be adjusted first, is achieved by moving the complete
rotating assembly towards the drive end:
a)
Pull off cover (P24) from the bearing frame and slacken housing clamp screws
(P16) - 2 off, tension screws (P23) - 2 off, and adjusting screw locknut (P38).
b)
While rotating shaft (B11) by hand, take up the back clearance by turning
adjustment screw (P19) against retaining plate (P22) until impeller (W3) is just
touching back liner (W4).
c)
Back off the adjusting screw through the saddle until the end of the screw
touches bearing frame (P14).
d)
Rotate the adjusting screw one turn. Check that impeller (W3) clears back liner
(W4).
e)
Tighten tension screws (P23), housing clamp screws (P16) and adjusting screw
locknut (P38).
NOTE:TENSION AND CLAMP SCREWS MUST BE TORQUE TIGHTENED TO THE TORQUE VALUES
LISTED IN TORQUE SETTING TABLES, SECTION 11.1.
Having completed the back clearance, the front clearance should be adjusted as follows:
5.
Front (Inlet Side) Clearance
NOTE:THE COMPLETE BEARING FRAME AND ROTATING ASSEMBLIES ARE MOVED TOWARDS
THE CASE WHEN SETTING THIS CLEARANCE.
a)
Slacken bearing frame screws (P11) and nuts (P1) on case bolts (P4).
b)
Insert a jack screw (P10) in each side of the frame flange and turn the screws
evenly to withdraw the bearing frame by approximately 4mm.
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c)
Unscrew the jack screws completely.
d)
Remove the case shim sets (P3).
e)
Reduce the gap between the bearing frame flanges and base/case support
(P13) by evenly tightening two diametrically opposite case nuts (P1) and bolts
(P4) until impeller (W3) touches case (W1).
f)
Measure the gap between the bearing frame and the base/case support .
Assemble case shims to a thickness just greater than the gap measured.
g)
Slacken off the two case bolts. Retract the bearing frame slightly and fit the
shims.
h)
Tighten case nuts (P1) and bolts (P4) evenly to the required torque loading.
Check that the impeller rotates freely. Add shims as necessary if the impeller
fouls the case after tightening.
NOTE: IMPELLER SHOULD BE AS CLOSE TO THE CASE AS POSSIBLE WITHOUT FOULING IT.
i)
Tighten bearing frame screws (P11) to the required torque.
6.
If fitted, reset the mechanical seal.
7.
Re-connect the drive belt or half coupling as applicable making sure that the drive is
aligned correctly. Adjust as necessary to obtain the correct alignment.
8.
Fit all safety guards.
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9.5.2
(i)
Hydraulic parts and frame - dismantling and fitting
Opening and closing the pump – fixed base
WARNING
MAKE SURE THAT ALL SLINGS, SHACKLES, ETC. ARE OF ADEQUATE LOAD CARRYING CAPACITY.
APPROXIMATE WEIGHTS OF MAJOR COMPONENTS ARE PROVIDED IN SUB-SECTION 11.3.
LIFTING POINTS INCORPORATED IN INDIVIDUAL COMPONENTS ARE INTENDED SOLELY FOR LIFTING
THAT SPECIFIC COMPONENT. NEVER USE THESE FOR LIFTING ASSEMBLIES OF COMPONENTS.
1.
General
The base (L) supports the case, the bearing and the rotating assemblies. See Figure
9.5.2-1. Bosses (D) cast in the frame are used to mount the drive motor overhead, if
required.
Slots in the base vertical plate provide locations for case fixings (B). The top and bottom
dead centre holes in the vertical plate are for the case clamp fixings (C). This method of
attachment allows the case to be installed with the outlet in a number of positions - see
‘General Arrangement’, section 2.6.
F
G
H
P
C
D
B
E
C
L
L
Figure 9.5.2-1 Bareshaft pump (typical)
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Shims (P) between the case and bearing frame are used to adjust the front running
clearance between the impeller and the case. For ease of assembly, case fixings (B)
locate in slots around the frame's front flange. The inner flange of the frame provides a
spigot for an expeller ring or a stuffing box. Threaded holes are provided in the flange for
withdrawal screws (E).
Openings (F) in each side of the body give access to the gland and water flushing
connection if fitted. Lubrication points are provided for the bearings. Other openings in
the top (G) or side of the frame body give access to the bearing cylinder tension screws,
saddle screws and impeller adjustment screw.
2.
Inspection of wearing parts
Inspection of wearing parts can be carried out by either removing the case or by removing
the bearing frame assembly, ie. front or back pull-out method. The method will depend on
the installation and ease of access to the pump.
The "back pull-out" method simplifies inspection and site maintenance. Alternatively, the
pumping parts can be removed from the front after removing the pipework.
Figure 9.5.2-2 Using back pull-out method avoids having to disturb the pipe-work
3.
Preparing for disassembly
Figure 9.5.2-1 and parts list drawings in section 10.4 identify parts referenced in this
section.
a)
Run the pump on clean water or flush clean the inside of the case.
b)
Isolate the pipework and drain the pump case.
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4.
5.
c)
Isolate the drive motor and attach suitable warning plates to the relevant
switches. It is advisable to remove the fuses and/or lock the isolator open to
prevent accidental starting.
d)
Where fitted, a mechanical seal requires setting for disassembly and section
9.5.3 would provide the relevant instructions.
e)
Disconnect the flush water tapping, if fitted.
Opening the pump – Back Pull-Out Method
a)
Remove the drive guard and disconnect the belt drive or direct coupling as
applicable.
b)
Remove the bearing frame screws (P11) and washers (P12).
c)
Remove case fixings (B). Keep them safe for reassembly. (Leave case
clamping fixings (C) in position to support the case.)
d)
Use jacking screws (P10) to ease apart the case and the rotating assembly by
about 6 mm.
e)
Remove case shims (P3) and jacking screws (P10).
f)
Attach a suitable sling through the bearing frame. Take the weight of the frame
assembly and withdraw it from the case, complete with back liner and impeller.
Opening the pump – Front Pull-Out Method
a)
Disconnect the inlet and outlet pipework from the pump.
NOTE: METAL PUMPS ARE EQUIPPED WITH INLET AND OUTLET FLANGE GASKETS (F2, F4).
ENSURE THAT THESE ARE SAVED FOR REASSEMBLY. RUBBER PUMPS HAVE INTEGRAL
GASKETS.
b)
Note the position of the outlet to ensure correct reassembly.
c)
Support the case in slings –cases for large pumps incorporate lugs (H) for
attaching lifting shackles.
d)
Remove case fixings (B & C). Keep them safe for reassembly.
e)
Use jacking screws (P10) to ease apart the case and the rotating assembly.
f)
Withdraw the case over back-liner (W4) and impeller (W3) and lower it onto a
suitable support.
g)
Remove jacking screws (P10).
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6.
Closing the pump
a)
If the Front Pull-Out Method was used:
i/ Lift and push the case over impeller (W3), onto back-liner (W4) and against
the vertical plate. Ensure that case fixings (B) enter their respective holes
around the flange joint.
ii/ Locate and secure the case to the vertical plate by fitting the upper and
lower casing clamp fixings (C) in the case slots provided.
b)
If the Back Pull-Out Method was used:
i/ Lift and offer the complete bearing frame and rotating assembly onto the
base/case-support and push the impeller and back liner into the case with
approximately a 30mm gap between the bearing frame flange and the
vertical plate.
ii/ Insert bearing frame screws (P11) and washers (P12). Do not tighten at this
stage.
c)
Set the impeller front clearance –see section 9.5.1.
d)
Check the impeller for freedom of rotation.
NOTE: AFTER FINAL ADJUSTMENT, THE BACK-LINER WILL NORMALLY PROTRUDE
SLIGHTLY INTO THE CASE –EXCEPT FOR HM50 AND HM75 WHEN FITTED WITH
INDUCED FLOW IMPELLERS WHICH USE A FLAT BACK-LINER.
e)
Tighten all fixings (B & C) to the torque values given in sub-section 11.1.
f)
If the Front Pull-Out Method was used:
Check inlet and outlet gaskets and re-connect the respective pipework.
CAUTION
REFER TO SECTION 6.5 BEFORE RENEWING PIPE FLANGES.
g)
If the Back Pull-Out Method was used:
i/
ii/
iii/
iv/
Tighten the bearing frame screws.
If fitted, reset the mechanical seal for operation.
If fitted, reconnect the flush water tapping.
Fit the drive belts or connect the drive coupling, ensuring that they are in
correct alignment.
v/ Fit and secure the drive safety guard and the gland guard in position.
vi/ Check that all fixings are secure.
vii/ Remove warning plates and safety locks from power switches and restore
power supply to the motor.
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9.5.2
(ii)
Hydraulic parts and frame - dismantling and fitting
Wet-end - disassembly and reassembly
1.
General
Case (W1), impeller (W3) and back-liner (W4) are high quality, high-chrome iron castings.
Larger size pump cases are ribbed and incorporate a number of lifting lugs. The inlet and
outlet branches are fitted with joint seals (F2, F4) and split flanges (F1, F3) to provide a
leak-proof and secure pipework connection.
The back-liner, which forms the rear face of the case, is attached to bearing frame (P14)
by tee bolts (W19) and hexagon-headed nuts (W20). For ease of assembly, the bolts are
retained in the slots by means of a rubber strap (W18). O-rings (W6) are used to seal the
back liner and the case.
The wide choice of impellers available permit the most efficient case-impeller combination
to be adopted for each application.
2.
Removing impeller (W3) and back-liner (W4)
a)
If an impeller release mechanism is fitted refer to section 9.5.2 (iii); otherwise,
insert a suitable bar between two impeller vanes and lock the bar against a
suitable static object. Apply a shock load by turning shaft (B11) in a direction
opposite to the pump rotation. Alternatively, lock the shaft and shock the
impeller. Sub-section 2.1.2 identifies the direction of rotation of the pump during
operation.
b)
Steady and suitably support impeller (W3) as it moves off shaft (B11).
DANGER OF
EXPLOSION
DO NOT
APPLY
HEAT
Figure 9.5.2-A Removing impeller (W3)
Figure 9.5.2-B Do not apply heat in order
to remove the impeller
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c)
Remove nuts (W20) from the four back liner bolts (W19) and withdraw back
liner (W4). The bolts are retained in position by a rubber strap.
WARNING
BACK-LINERS ON LARGE PUMPS ARE EXTREMELY HEAVY. USE THE BACK-LINER LIFTING TOOL
RECOMMENDED IN SECTION 9.3.
3.
4.
Inspection
a)
Clean and inspect case (W1), impeller (W3) and back-liner (W4) for severe
scoring, extensive wear, pitting, corrosion and damage. Renew if necessary.
b)
Inspect back-liner seal (W6). Renew it , if it shows any signs of damage.
c)
Refer to sections 9.5.3 and 9.5.4 for Shaft Seal and Bearing Maintenance.
Assembly
a)
Ensure that the impeller release mechanism, where applicable, and the shaft
seal components are in position. See parts list drawings in section 10 for
details.
b)
Fit back-liner seal (W6) into the groove around back-liner (W4). Grease the
seal to aid assembly.
c)
Locate back-liner bolts (W19) into the lugs around back-liner (W4) and retain in
position with back-liner bolt retaining strap (W18).
d)
Offer back-liner (W4) to the frame, engaging back liner bolts (W19) in the frame
holes.
WARNING
WHERE APPLICABLE, USE THE BACK-LINER LIFTING TOOL RECOMMENDED IN SECTION 9.3.
e)
Fit and tighten nuts (W20) to the correct torque (refer to sub-section 11.1).
NOTE:WHEN FITTING NEW PARTS TO PUMPS FITTED WITH EXPELLER TYPE SHAFT SEALS,
IT MAY BE NECESSARY TO ADJUST THE BEARING ASSEMBLY AXIALLY USING THE
ADJUSTING SCREW TO PREVENT THE EXPELLER FOULING THE BACK LINER.
f)
Clean the thread on the shaft and grease with appropriate lubricant or anti-seize
compound.
g)
Fit impeller gasket (W17).
h)
Lift impeller as shown in Figure 9.5.2-A and mount it onto the shaft end.
i)
Block impeller (W3) using a bar inserted in between two of its vanes, then turn
the shaft with the special crank-handle until the impeller is locked tight –refer to
sub-section 9.3.
j)
Set the impeller back clearance, where applicable – see section 9.5.1.
k)
Apply grease liberally around back-liner seal (W6) to assist entry into case
(W1).
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9.5.2
Hydraulic parts and frame - dismantling and fitting
(iii) Impeller Release Mechanism (IRM)
Not applicable.
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9.5.2
Hydraulic parts and frame - dismantling and fitting
(iv) Hydraulic system
Not applicable
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9.5.3
Shaft seal - dismantling and fitting
Metso Minerals Mechanical Seal (H3) – Double
1.
General observations
A large variety of mechanical seals are suitable for use with the Metso Minerals Slurry
pumps. The Metso Minerals Mechanical Seal, however, is designed to provide excellent
performance when fitted to Metso Minerals Slurry pumps.
CAUTION
INSTRUCTIONS INCLUDED IN THIS SECTION ARE CRITICAL TO THE CORRECT INSTALLATION AND
OPERATION OF THE SEAL. FAILURE TO OBSERVE THEM MAY CAUSE IRREPARABLE DAMAGE TO BOTH
THE SEAL AND THE PUMP.
INSTALLATION AND REMOVAL OF THE SEAL MUST ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL
WHO HAVE READ AND UNDERSTOOD THE INSTRUCTIONS.
ENSURE THAT THE PUMP IS NOT EXPOSED TO FREEZING CONDITIONS AND ALWAYS DRAIN THE
SEAL’S WATER FLUSH SYSTEM OF ALL LIQUID AS PREPARATION FOR ANY MAJOR SHUTDOWN.
Information on pump vibration is provided in section 2. To identify parts referenced in this
section, see Figure 9.5.3-1 and parts list drawings in section 10.4 .
D
(2)
B
W31
C
(1)
(3)
[Quench liquid: (1) Inlet, (2) Outlet, (3) Drain]
Figure 9.5.3-1 Metso Minerals Mechanical Seal – Double
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2.
Operating considerations
The double acting Metso Minerals Mechanical Seal has silicon carbide seal faces on both
the product and the atmospheric sides. The seal requires flushing liquid at all times during
operation, otherwise the seal faces are destroyed within seconds.
NOTE: DEPENDING ON THE APPLICATION, THE FLUSHING LIQUID PRESSURE MAY BE EITHER HIGHER
OR LOWER THAN THE PUMP PRESSURE.
Flushing rate varies with shaft diameter, D, as shown in Figure 9.5.3-2. Total flushing rate,
Tf, is, however, dependent on both the shaft running speed, R, and shaft diameter, D (See
Table 9.5.3-1), and is calculated using the formula:
Total flushing rate, Tf = F × Rf
Where, Rf , is the shaft speed factor as tabulated in Table 9.5.3-2.
Frame Size
Shaft Diameter (mm)
FR250
FR300
47.5
63.0
FR400
FR500
75.0
95.0
FR600
111.7
FR750
120.0
Table 9.5.3-1 Frame size to shaft diameter correspondence table (Frame size for your
pump is stated in ‘Pump Specification’, section 1.3).
Flushing rate, F (l/min)
6
5
4
3
2
1
0
0
25
50
75
100
125
150
Shaft diameter, D (mm)
Figure 9.5.3-2 Variation of flushing rate with shaft diameter
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The required water quality is specified as follows:
R (rpm)
700
1150
1400
1750
2100
2450
2800
3150
3500
Rf
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
R (rpm)
3950
4200
4900
5250
5600
5950
6300
6650
7000
Rf
1.1
1.2
1.4
1.5
1.6
1.7
1.8
1.9
2.0
Solid particles
Particle size
Critical particle size
Permanganate value
Ferro content
Hardness value
:
:
:
:
:
:
max. 10 mg/l
10-50 µm
2 -5 µm (to be avoided)
max. 30 (free from humus)
max. 1 mg/l
max. 10° dH
Table 9.5.3-2 Shaft speed factor table
a)
Ensure that quench liquid is present at all times.
NOTE:SEALING LIQUID (WATER) MUST BE CIRCULATED AT 1 TO 2 BAR ABOVE SEAL PRESSURE.
CAUTIONS
THE MECHANICAL SEAL MUST NOT RUN WITHOUT QUENCH LIQUID, OTHERWISE THE SEAL WILL BE
DESTROYED WITHIN SECONDS.
MINIMUM FLUSHING RATE IS 0.5 LITRES PER MINUTE.
MAXIMUM PUMPING TEMPERATURE IS 75 °C.
b)
Check the leakage level of the seal periodically during operation. This is a
measure of the condition of the seal. If there is noticable leakage from the seal,
it should be renewed. It is recommended that a spare seal is held in stock to
allow immediate renewal. No maintenance is possible while the seal is
installed.
3.
Start-up
Before start-up, ALWAYS ensure that liquid is present in the quench system and that it is
fully vented.
4.
Disassembly
a)
Follow the appropriate procedure to stop the pump and isolate it from the power
supply.
b)
Flush the pump with clean water.
c)
Close the inlet and discharge valves and drain the pump.
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d)
Shut off and disconnect quench water connection to the seal.
e)
Gain access to the seal by opening up the pump using the Front or Back
Pull-Out method.
f)
With the impeller (W3) and backliner (W4) removed, slide the seal assembly off
the shaft. Remove and discard O-ring (W31).
WARNING
SHAFT SEALS FOR LARGE PUMPS ARE QUITE HEAVY. USE THE SPECIAL SHAFT EXTENSION TO
FACILITATES THEIR REMOVAL AND REFITTING –SEE SUB-SECTION 9.3.
5.
Inspection
Mechanical seals require specialist servicing, therefore, Metso Minerals provide a service
exchange facility and recommend that seals are returned for this convenient service.
Alternatively, repair kits for the seals are available on request. These include detailed
service instructions, however, repairs are carried out at the customer’s own risk.
a)
Ensure that the pump and bearings are in good condition.
b)
Check that shaft (B11) and mechanical seal (G31) are free from damage.
6.
Assembly
If the seal did not leak before dismantling it may be fitted back in the pump, otherwise a
new seal must be fitted.
a)
Check that O-rings (C) and (D) are in place.
b)
Mount mechanical seal assembly (G31) onto shaft (B11) and push it along until
its flange (B) makes contact with bearing frame (P14).
c)
Ensure that quench water outlet is as close as possible to the 12 O’clock
position.
d)
Assemble the rest of the pump as appropriate to the pull-out method used for
disassembly and take note of the following precautions:
i/
ii/
iii/
iv/
ensure that seal flange (B) is securely clamped between backliner (W4)
and bearing frame (P14);
fit a new O-ring (W31) before screwing on impeller (W3);
ensure that inlet and outlet quench liquid pipes are connected to the seal
and that quench liquid is available -see paragraphs (2) and (3) above for
details;
adjust impeller clearances.
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9.5.4
Shaft and bearing assembly - removal and fitting
The following instructions assume that the pump is installed complete with the drive unit
and is connected to the suction and discharge pipework.
1.
2.
Removal
a)
Remove the drive safety guard and disconnect the drive belts or drive coupling
as applicable.
b)
If necessary, remove the drive motor to provide sufficient space to withdraw the
bearing frame assembly from the case.
c)
Remove the wet end assembly (refer to sections 9.5.2 & 9.5.3)
d)
Where applicable, remove impeller release mechanism from the shaft – see
section 9.5.2 (iii).
e)
Remove the housing clamp (P29) and cover (P24).
f)
Slacken the tension screws (P23), adjusting screw (P19) and locknut (P38).
Remove the adjusting screw and retaining plate (P22).
g)
Remove the saddle screws (P20) and lift out the saddle (P18).
h)
Remove the grease nipple (B13) from the end cover at the wet-end of the shaft.
i)
Ease the shaft assembly rearwards out of the bearing frame. When possible,
especially on the larger pumps, fit a strop sling around the bearing housing to
take the weight as it is withdrawn completely from the frame. Remove the
tension block (P21) as the assembly is withdrawn.
j)
Place the shaft and bearing assembly on suitable supports, ideally wooden vee
blocks.
Re-fitting
a)
Clean and degrease the bore of the bearing frame. Coat the machined
surfaces with anti-seize compound.
b)
Using a suitable strop sling to lift the assembly, insert the shaft and bearing
assembly, threaded end first, into the bore of the frame.
c)
Rotate the bearing cylinder housing in the frame so that the tapped holes for the
saddle screws are uppermost. Fit the following parts into position:
•
•
•
•
•
d)
Tension Block (P21)
Adjusting Screw (P19) into the saddle
Saddle (P18) (Do not fit screws at this stage)
Retaining Plate (P22)
Housing clamps (P29) and Housing clamp screws (P16) - tighten temporarily.
Finally, position the bearing cylinder housing so that the saddle screws (P20)
can be inserted and fully tightened to the correct torque. See section 11.1.
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e)
Fit the grease nipple (B13) to the end-cover at the wet-end of the shaft.
f)
Where applicable, assemble impeller release mechanism to the shaft – see
section 9.5.2 (iii).
g)
Reassemble the gland.
h)
Reassemble the remainder of the pump.
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9.5.5
Shaft and bearings - disassembly and re-assembly
1.
General
The bearing assembly consists of a steel shaft onto the end of which the impeller is
screwed. The other end of the shaft is keyed to accept a coupling or belt drive
arrangement.
Heavy-duty, tapered roller bearings are used in various configurations as illustrated
schematically below:
S
G
G
S
Standard bearing assembly
S
G
G
S
Double dry-end bearing assembly for high belt loads
S
G
G
S
Double wet-end bearing assembly for high impeller loads
A lipseal backed by a V-ring (S), seals the bearings against dirt and other foreign matter.
Grease nipples (G) are fitted to allow periodic bearing lubrication. Grease is purged
through the bearing to remove any contamination.
The bearing assembly is secured in the bearing frame by a housing clamp, saddle block,
and adjusting screw. On larger size pumps, two housing clamps and two saddle blocks
with adjusting screws are used to adjust the shaft assembly axially.
The central portion of the bearing housing is colour coded to allow the assembly type to be
ascertained from the exterior. The band is visible, when the cover plate (P24) is taken off
the bearing frame (P14). Table 9.5.5-1 explains the coding.
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Table 9.5.5-1 Bearing assembly type colour coding
UNIT TYPE
STATUS
COLOUR CODE
Standard
New build
Mid Blue-18.E.53
Double dry-end
New build
Green
Double wet-end
New build
Yellow
Standard
Reconditioned
Red
Double dry-end
Reconditioned
Red with green band
Double wet-end
Reconditioned
Red with yellow band
2.
Disassembly
a)
Remove the flinger (B1) from the wet-end of the bearing cylinder.
b)
Support the shaft and bearing assembly vertically on blocks on the end cover
with the impeller thread downwards.
c)
Remove the following parts from the dry-end of the bearing cylinder housing
(B14):
• End Cover Screws (B5)
• End Cover (B2.2)
• Primary (B22.2 ) and secondary (B19.2) seals.
NOTE: MAKE A NOTE OF THE NUMBER OF SHIMS FITTED, TO AID ASSEMBLY.
3.
d)
Lift out the shaft and bearings.
e)
Tap or press off the bearings.
NOTE:THREE-BEARING ASSEMBLIES HAVE AN INNER AND OUTER SPACER FITTED
BETWEEN THE BEARINGS AT THE TWO-BEARING END.
f)
Lay the bearing cylinder housing horizontally on vee blocks.
g)
Remove the end cover and shims from the wet-end.
h)
Wash all parts in a suitable cleaning solvent and dry carefully.
Inspection
a)
Inspect the bearing housing internally for excessive wear in the area of the roller
bearing outer races. Check that all threaded holes are clear and that the
threads are undamaged.
b)
Check for damaged seals. Inspect end covers for damage and ensure that
grease passages are clear.
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4.
c)
Carefully inspect the roller bearings, cages and races for wear, damage and
corrosion. After inspection, dip the bearings in gear oil and wrap them in a
clean cloth or paper to protect them until installation.
d)
Check the condition of the shims.
e)
Examine the shaft for damage and corrosion. Remove any nicks and burrs with
a carborundum stone.
f)
Inspect the shaft sleeve and gaskets for deterioration, damage and wear.
Renew any gaskets which are suspect.
g)
Renew any defective components.
Assembly
a)
Slide the bearing inner races and bearing cages onto shaft (B11). Ensure that
the large outer diameter of the inner races are facing inwards on the shaft.
NOTE: ON ASSEMBLIES WITH TWO BEARINGS AT ONE END, THE ARRANGEMENT IS AS
FOLLOWS: INNER RACE, INNER SPACER, OUTER RACE, OUTER SPACER, INNER
RACE.
b)
Press the bearing inner races onto the shaft so that they are tight against the
inner shoulders of the shaft.
NOTE: THE BEARINGS MAY BE HEATED IN OIL OR IN A BEARING HEATER TO A MAXIMUM
OF 121 °C FOR EASE OF ASSEMBLY.
c)
Coat the shaft between the bearings with a suitable corrosion preventive
solution.
CAUTION
DO NOT GREASE THE BEARING LANDS OF THE BEARING HOUSING. THESE LANDS
SHOULD BE CLEANED WITH A PROPRIETARY DEGREASANT AND THOROUGHLY DRIED.
ENSURE THAT THE LANDS ARE FREE FROM ALL DIRT, GRIT AND CONTAMINANTS BEFORE
ASSEMBLING.
d)
Push or tap a bearing outer race into the bearing cylinder housing (B14) at the
end nearest the tapped saddle screw (P20) location holes (wet-end) and
position it just below the end face of the housing. The smaller inner diameter
must be outermost. See the assembly diagram for correct orientation if in
doubt. Stand the housing on one end to assist assembly.
e)
Fit grease nipples (B13) to end covers, if not already fitted. Purge greaseways
with fresh grease using a grease gun and wipe excess grease away. Ensure
that the end covers are kept clean.
f)
Fit the secondary seal (B19.1) into the end-cover.
g)
Place one thick end-cover shim over the spigot of end-cover (B2.1) and fit it to
bearing cylinder housing (B14) using screws (B5) so as to push the outer
bearing race into the housing. Position the end-cover so that the bearing
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grease hole will be accessible when the bearing cylinder assembly is fitted to
bearing frame (P14). Tighten the screws (B5) evenly and to the correct torque.
See Torque Table, section 11.1.
h)
Fit shaft (B11) into bearing cylinder housing (B14) with its threaded end
protruding from the wet-end cover (B2.1). It is recommended that the housing
is supported vertically in a secure stand to give sufficient clearance underneath
the shaft –see Figure 9.5.5-1.
A
B
E
E
C
D
Figure 9.5.5-1 Bearing cylinder housing support & bearing clearance: Shaft(A),
Dial test indicator (B), Bearing cylinder housing (C), Support
stand (D), Securing screws (E).
i)
Fit the bearing outer race into the bearing cylinder housing at the dry-end and
press it into position using dry-end cover (B2.2) until the shaft becomes stiff to
turn.
j)
Assemble the pack of shims removed during disassembly.
k)
Remove cover (B2.2), fit the shims over the cover’s spigot, then re-fit the cover
to the housing.
l)
Tighten screws (B5) evenly and to the correct torque.
IMPORTANT NOTE
STRIKE THE INDIVIDUAL ENDS OF THE SHAFT TO ENSURE THAT THE BEARING RACES ARE HARD
UP AGAINST THE END COVER BEFORE CHECKING THE BEARING CLEARANCE.
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Table 9.5.5-2 Bearing clearances
FRAME SIZE
CLEARANCE (END-FLOAT), MM
FR250
0.075 to 0.125
FR300
0.075 to 0.125
FR400
0.100 to 0.150
FR500
0.100 to 0.150
FR600
0.150 to 0.200
FR750
0.180 to 0.250
m)
Check the bearing clearance for the size of pump (See Table 9.5.5-2) using a
dial test indicator on the shaft end.
NOTE:IDEALLY, THE INDICATOR SHOULD BE FITTED TO A MAGNETIC BASE LOCATED ON THE
END-COVER. BY MOVING THE SHAFT BACKWARDS AND FORWARDS THE END
CLEARANCE MAY BE READ ON THE INDICATOR (SEE FIGURE 9.5.5-1).
n)
Remove or add shims as necessary to obtain the correct clearance.
NOTE:ROTATE THE SHAFT WHILE CHECKING THE CLEARANCE TO ENSURE CORRECT
SEATING OF THE BEARING ROLLERS.
o)
Having set the clearance, remove dry-end cover (B2.2) and its shim set.
p)
Remove the dry-end bearing outer race and withdraw the shaft assembly.
q)
Pack the required quantity of grease into both bearing cages -see Lubrication
sub-section 9.4.
NOTE:WHEN HAND PACKING, FORCE GREASE THROUGH THE BEARING UNDER THE CAGE
FROM THE LARGE TO THE SMALL END TO ENSURE THOROUGH DISTRIBUTION.
ALWAYS USE THE CORRECT QUANITY OF GREASE. OVER OR UNDER GREASING
CAN BE DETRIMENTAL TO THE LIFE OF THE BEARING.
r)
Re-fit shaft (B11) into bearing cylinder housing (B14).
s)
Re-fit the dry-end bearing outer race into the housing.
t)
Fit secondary seal (B19.2) into end cover (B2.2).
u)
Fit the shims and refit end-cover (B2.2) to the housing, positioning the grease
hole such that it will be accessible when the bearing cylinder assembly is fitted
to bearing frame (P14).
v)
Tighten screws (B5) evenly and to the correct torque.
w)
With the bearing cylinder housing now supported horizontally, lubricate the
parts with grease and slide the shaft spacer (B6) with the shaft spacer seal
(B16) into position taking care not to damage the seal. Apply a light coating of
grease to the backs of the secondary seals (B19.1) & (B19.2) and push the
primary seals (B22.1) & (B22.2) into position making firm contact with the
secondary seals.
x)
Fit the flinger (B1).
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9.5.6
Pump drive - removal and re-fitting
•
V-drive
1.
Dismantling the drive
WARNING
ENSURE THAT THE PUMP MOTOR IS ISOLATED AND THE ISOLATOR IS LOCKED IN THE ISOLATED
POSITION BEFORE REMOVING THE DRIVE GUARD.
TO PREVENT 'REVERSE MOTORING' OF THE PUMP, ENSURE THAT THE DISCHARGE LINE IS ISOLATED
BEFORE REMOVING THE DRIVE GUARD.
a)
Slacken off the screws securing the upper drive guard to the lower and remove
the upper drive guard;
b)
slacken off the motor support nuts, thus allowing the drive motor to move
toward the bearing frame and slackening the drive belts, until the belts can
easily be removed by hand;
c)
remove the drive belts;
d)
remove the pump and motor pulleys as described in Pulley – removal;
e)
remove the drive guard set screws and washers and lift the lower drive guard
from the assembly;
f)
if required, the motor, or motor and support plate assembly, may be removed
from the pump unit.
2.
Reassembling the drive
The procedure is as follows;
a)
fit the motor and/or motor support plate if these have been removed;
b)
fit the lower drive guard to the pump unit and, ensuring the guard butts against
the top of the upper bearing housing cover, secure it in position using the drive
guard set screws and washers;
c)
check that the motor butts against the underside of the lower drive guard. If this
is not so then slacken off the motor mounting nuts and bolts, move the motor so
that it butts against the lower drive guard, and tighten the motor mounting nuts
and bolts on completion;
d)
fit the pump pulley as described in Pulley - fitting, ensuring a clearance of
approximately 10mm between the underside of the pulley and the lower drive
guard;
e)
fit the motor pulley as described in Pulley - fitting, ensuring that it is correctly
aligned with the pump pulley as described in Drive alignment;
f)
fit the drive belts and tension as described in Drive belt tension;
g)
fit the upper drive guard to the lower and secure in place using the screws
provided.
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3.
Pulley – removal
a)
Slacken, by several turns, all screws in the Taper Lock® bush. Remove one or
two, according to the number of jacking holes (shown as ‘!’ in Figure 9.5.6-1).
b)
Oil the thread of each screw, the point of grub screws and under the head of
cap screws. Insert the screws into the jacking holes.
c)
Tighten the screws alternately
until the bush is loosened in the
pulley and the assembly is free
on the shaft.
d)
Withdraw the pulley, complete
with Taper Lock® bush.
Figure 9.5.6-1 Taper Lock ® screw positions
4.
Pulley - fitting
a)
If a new pulley is to be fitted then remove the protective coating from the bore
and outside of the Taper Lock® bush, and bore of the pulley;
b)
ensure that the mating tapered surfaces are completely clean and free from oil
or dirt, insert the bush into the pulley so that the holes are aligned;
c)
sparingly oil the thread and point of grub screws, or thread and under the head
of cap screws; place the screws loosely in holes in the pulley, shown as '
Figure 9.5.6-1;
' in
d)
clean the shaft, fit the key (if used), and fit the pulley to the shaft as one unit,
locating in the desired position (note that the bush will nip the shaft first and the
pulley will be drawn onto the bush as the screws are further tightened);
e)
using a suitable hexagon wrench, tighten the screws gradually and alternately
until the torque loading given in Table 9.5.6-1 is achieved;
f)
using a suitable block to protect the bush, hammer against the large-end of the
bush (this ensures that the bush is seated squarely in the bore of the pulley);
g)
re-tighten the screws to the torque specified in Table 9.5.6-1;
Bush size
Torque(Nm)
Screws
1008 1108 1210 1610 1615 2012 2517 3020 3030 3525 4030 4535 5040
5.6
5.6
qty
2
2
size
(BSW)
¼"
¼"
20
20
20
30
50
90
90
2
2
2
2
2
2 2
3
/ 8"
3
/ 8"
3
/ 8"
7
/16" ½"
5
/ 8"
5
115 170 190 270
3
/ 8"
½"
3
5
/ 8"
3
¾"
3
7
/ 8"
Table 9.5.6-1 Taper Lock® screw torque loading
h)
repeat the hammering and tightening a further once or twice to achieve
maximum grip on the shaft;
i)
after the drive has run under load for a short time, stop the pump and check the
screws for tightness;
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j)
5.
fill the empty holes with grease to exclude dirt and other arisings.
Drive belt re-fitting
CAUTION
DO NOT USE WEDGES, LEVERS ETC. TO FORCE DRIVE BELTS INTO POSITION. THIS PRACTICE WILL
RESULT IN INTERNAL DAMAGE TO THE BELTS AND PREMATURE BELT FAILURE.
a)
Ensure that the motor support nuts are slackened sufficiently to allow the drive
belts to be fitted to the pulleys by hand and fit the drive belts;
b)
tension the drive belts as described in Drive belt tension;
c)
ensure that the pulleys are correctly aligned as described in Drive alignment;
d)
lock the drive motor in position by tightening the motor support nuts on the
bearing frame side, and recheck the alignment and tension;
e)
fit the upper drive guard to the lower and secure in position with the screws
provided.
6.
Drive belt tension
The high performance of modern belts, particularly wedge belts, cannot be achieved
without correct tensioning. To check for correct tension, refer Figure 9.5.6-2 and Table
9.5.6-2 and proceed as follows:
a)
Install the belts to be a snug fit around the pulleys;
b)
Spin the pulleys 3-4 revolutions to bed belts into the pulley grooves.
c)
Multiply the distance between the motor and pump pulley centres (in metres) by
16. This gives the deflection distance in millimetres.
d)
For belts already in service, the belt tension is correct when on applying the
appropriate ‘basic’ setting force at right angles to one belt at the centre of the
span, the belt deflects by the previously calculated distance.
NOTE:FOR SINGLE BELT DRIVES PLACE A STRAIGHT EDGE ACROSS THE TWO PULLEYS TO ACT
AS A DATUM FOR MEASURING THE AMOUNT OF DEFLECTION. TO CHECK TENSION IN
BANDED BELTS, USE A BAR ACROSS THE BAND WIDTH TO ENSURE EVEN DISTRIBUTION
OF THE FORCE. THEN DIVIDE THE FORCE MEASURED BY THE NUMBER OF BELTS IN THE
BAND FOR COMPARISON WITH THE VALUES IN THE TABLE. FOR SHORT CENTRE
DISTANCE DRIVES WHERE THE DEFLECTION OF THE BELT IS TOO SMALL TO MEASURE
ACCURATELY, DOUBLE BOTH THE DEFLECTION AND THE SETTING FORCE VALUES.
e)
If a new belt is being installed, tension it to the ‘1.25×’ setting.
f)
Refit the guards and run the drive under load for 15 to 20 minutes.
g)
Stop the drive, check the tension as previously described and re-set to the
‘basic’ value, if necessary.
NOTE:COGGED RAW EDGED BELTS SHOULD BE RESET TO ‘1.25× ‘SETTING
h)
There should be no need for further attention during the life of the belts.
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When comparing forces with the force range given in Table 9.5.6-2, if the measured force
falls within the given range, the tension should be satisfactory. A lower measured force
indicates under-tensioning while a higher measured force indicates over-tensioning.
Under-tensioning can give rise to belt slip, together with resultant excessive belt wear and
power loss. Over-tensioning will cause excessive wear to the bearings.
WARNING
ALWAYS REPLACE THE DRIVE GUARD BEFORE RUNNING THE PUMP.
BELT SECTION
SMALL PULLEY
DIAMETER (mm)
FORCE REQUIRED TO DEFLECT BELT 16mm
PER METRE OF SPAN
BASIC SETTING (N)
‘1.25×’ SETTING (N)
56 to 71
75 to 90
95 to 125
over 125
80 to 100
106 to 140
150 to 200
over 200
112 to 160
170 to 224
236 to 355
over 355
224 to 250
265 to 355
over 375
335 & above
56 to 100
80 to 140
125 to 200
200 to 400
355 to 600
SPZ
SPA
SPB
SPC
8V
Z
A (& HA banded)
B
C
D
16
18
20
22
22
30
36
40
40
50
62
65
70
92
115
150
5 to 7.5
10 to 15
20 to 30
40 to 60
70 to 105
20
22
25
28
28
38
45
50
50
62
77
81
87
115
144
190
—
—
—
—
—
Table 9.5.6-2 Belt tension forces
SPAN
FORCE
DEFLECTION
Figure 9.5.6-2 Drive belt tension diagram
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Care and maintenance
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Slurry Pump
7.
Trouble shooting
a)
Small cracks on V-belt side and base
This is generally caused by shortage of belt tension but excessive heat and/or
chemical fumes can also give same failure.
b)
V-belt swelling or softening
This is caused by excessive contamination by oil, certain cutting fluids or rubber
solvent.
c)
Whipping during running
This is usually caused by incorrect tensioning, principally on long centre drives.
If a slightly higher (or lower) tension does not cure the problem there may be a
critical vibration frequency in the system which requires re-design or use of
banded belts.
8.
Drive alignment
It is important that drive belts are correctly aligned. Belt misalignment results in increased
noise, increased power absorption and reduced belt life. Figure 9.5.6-3 shows examples of
parallel and angular misalignment.
<4mm/m
PARALLEL MISALIGNMENT
<1mm/m
ANGULAR MISALIGNMENT
Figure 9.5.6-3 Drive belt misalignment
The motor and pump pulleys are fitted to their shafts with Taper Lock® bushes. This
method allows the pulleys to be fitted at any position on the shaft, subject to certain
constraints (length of shaft keyway etc.). However, to reduce bearing loading, it is
important that each pulley is fitted close to the motor body/bearing frame.
The maximum permitted misalignment for the pump is ±4mm/m run parallel misalignment
and ±1° angular misalignment. Details of alignment procedures are given in section (drive
assembly - fitting).
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Care and maintenance
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Slurry Pump
CAUTIONS
V-BELTS FROM DIFFERENT MANUFACTURERS MUST NOT BE MIXED ON THE SAME DRIVE.
THE
SLIGHT DIFFERENCES IN CROSS SECTION AND INTERNAL DESIGN WILL SERIOUSLY AFFECT RUNNING
LIFE. FOR THE SAME REASON, NEW AND USED V-BELTS SHOULD NOT BE USED ON THE SAME DRIVE.
WHEN REPLACING BELTS, ALWAYS REPLACE THE ENTIRE SET TOGETHER.
TO PREVENT ABRASION AND DETERIORATION, THE BELT SYSTEM MUST BE KEPT CLEAN AND FREE
FROM EXCESSIVE HEAT, OIL, GREASE AND CHEMICAL FUMES. IF THIS IS NOT POSSIBLE THEN
SPECIAL BELTS SHOULD BE SPECIFIED.
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04-W08
Care and maintenance
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Slurry Pump
9.6
Fault finding
9.6.1
General
Use the checklist provided to quickly establish the cause of any running problems. The
checklist assumes that the equipment normally operates satisfactorily.
WARNING
WHERE POSSIBLE CHECKS MUST BE CARRIED OUT WITH THE POWER SUPPLY SECURELY ISOLATED.
WHERE POWER IS REQUIRED FOR CARRYING OUT THE CHECKS, TAKE EVERY PRECAUTION
PRESCRIBED IN ORDER TO AVOID INJURY TO PERSONNEL. ELECTRICAL WORK MUST ONLY BE
CARRIED OUT BY A FULLY QUALIFIED ELECTRICIAN.
A multimeter, a test lamp and appropriate circuit diagrams will be required to carry out
checks on electrical equipment.
NOTE: IF ALL FAILS, CONTACT METSO MINERALS FOR FURTHER ADVICE.
9.6.2
Pump fails to start
Is power supply live ?
No⇒ Check that:
Yes
⇓
⇓
⇓
⇓
⇓
•
•
•
•
•
•
Can pump be started manually ?
No⇒ Is there a fault with:
Yes
⇓
⇓
⇓
• level control equipment ?
• other monitoring or control equipment ?
mains switch is closed;
starter and its fuses are intact;
control voltage is available for starting;
overload protection has been reset;
all phases are live;
power cable to motor is not damaged.
Consult monitoring equipment documentation
and change any faulty equipment.
Is the shaft jammed ?
Yes⇒ Securely isolate the power supply.
No
⇓
⇓
⇓
• Remove the belt guard and try to rotate the
⇓
⇓
⇓
• Dismantle the drive and check that both the
WH22AAAAAA0EN_03B.DOC
pump shaft by hand.
• Dismantle the pump and clean behind the
impeller. See section 9.5.2. Flush out the
pump and the pump sump.
motor and pump shaft can be rotated. Fit
new bearings if necessary. See section 9.5
and the motor manufacturer’s instructions.
JAN
04-W08
Care and maintenance
1/3
Slurry Pump
9.6.3
The pump starts but the motor protection trips
Has flow path or pipe run been
modified ?
No
⇓
⇓
Yes⇒
Is motor protection setting too low ?
No
⇓
⇓
Yes⇒
Is shaft jammed or hard to turn?
No
Yes⇒
⇓
⇓
⇓
⇓
• Remove the belt guard and try to rotate the
⇓
⇓
⇓
• Dismantle the drive and check that both the
⇓
• Check that pump clearances are correct.
• Alter the flow path or pipe run, or adjust the
rating of the drive motor and pump to suit
new operating conditions.
• Check against the motor rating plate and
adjust as necessary
• Securely isolate the power supply.
pump shaft by hand.
• Dismantle the pump and clean behind the
impeller. See section 9.5.2. Flush out the
pump and the pump sump
motor and pump shaft can be rotated. Fit
new bearings if necessary. See section 9.5
and the motor manufacturer’s instructions.
See section 9.5.1.
9.6.4
The pump is running but the flow rate is too low or nil
Has operating conditions or pipe run
been modified ?
Yes⇒
• Alter the operating conditions, the pipe run,
No
⇓
⇓
or adjust the rating of the drive, motor and
pump to suit new operating conditions.
Has leakage been detected in plant ?
No
⇓
⇓
WH22AAAAAA0EN_03B.DOC
JAN
Yes⇒
• Renew or seal the leaking parts.
04-W08
Care and maintenance
2/3
Slurry Pump
9.6.5
The pump runs unevenly or vibrates
Is the inlet flow uneven or is the pump
drawing air ?
Yes⇒
• Either adjust the feed to the pump, or adjust
No
⇓
⇓
the rating of the drive, motor and pump to
suit the operating conditions.
Are all valves open and are the pipes
clear ?
Yes
⇓
⇓
Is the impeller clogged ?
No
⇓
⇓
No⇒
• Remedy the fault.
Yes⇒
• Clean the impeller -see Dismantling and
Assembly, section 9.5.
9.6.6
Abnormal leakage from the shaft gland
See Shaft Seal Removal and Fitting, section 9.5.3.
WH22AAAAAA0EN_03B.DOC
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04-W08
Care and maintenance
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Slurry Pump
10
SPARE PARTS
10.1
Recommended stock of spares
To reduce the length of time a pump is out of service, it is advisable to always keep in
stock a set of the recommended spare parts listed in this section. Please refer to the table
below for part item number references.
Item
10.2
Part Reference
Case (complete volute)
W1
Impeller
W3
Back-liner
W4
Metso Minerals mechanical seal
G31
Bearing cylinder assembly
B99
Set of seals
B98
Storage of spares
See section 1.2.5.
10.3
Spares ordering procedure
To assist our Spares Department process your order quickly, customers are requested to
provide the following information when ordering spares:
•
•
•
•
•
Model and Size of pump
Serial Number
Build Number
Approximate date of purchase
Part Number and Description of Required Spare Parts
This information should then be forwarded to the local Metso Minerals branch for action - see sub-section 1.4.
WH23AM1S040EN_03C.DOC
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04-W08
Spare parts
1/1
Slurry Pump
10.4
Spare part drawing
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04-W08
Spare parts
1/1
Slurry Pump
F3
F4
W1
W3
W2
W6
W18
W19
W4
W20
W21
W17
F2
F1
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04-W08
Spare parts
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Slurry Pump
D
(2)
B
W31
C
(1)
(3)
G31
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1/1
WH24AA1B013XX_04B.DOC
A
A
JAN
A-A
B5
B2.2
B19.2
B10
B11
B22.2
B13
½"BSP
B3
B8
B14
B19.1
B2.1
B22.1
B1
B16
B6
Slurry Pump
04-W08
Spare parts
1/1
WH24AA1F010XX_01B.DOC
JAN
04-W08
P13
P12
P11
P14
P30, P31, P32
P15
P16
P29
P18
P17
P20
P38
P28
P24
P21
P19
P10
P23
P22
P3
P1
P1
P1
P9 P39
P8
P6
P5
P4
P34 P35 P8
P1 P39
P2
P2
V
Slurry Pump
Spare parts
1/1
Pump HM100 MEC HC
Parts list
Item
W01
W03
W04
W06
G31
B01
B02.1
B02.2
B03
B06
B08
B10
B11
B14
B99
Part No.
Description
Qty Unit weight
Kg
PD771010
PD731047
PD741041
SA982898
Wear parts
Case
Impeller
Back liner
O-ring (incl. in w04)
1
1
1
1
77.00
23.00
13.80
0.00
SABA063-P-NPT
Shaft seal
Mechanical seal
1
0.00
SA500218-2
PDCH1843-SS
PDCH3074-SS
PD720025
PDCB810
Z0370576
SA899018-130
PDCH1844
PD720004
PDWB041-S464
Bearing assembly parts
Flinger
End cover
End cover
Shim set
Shaft spacer
Bearing
Key
Shaft
Bearing cylinder housing
Bearing/shaft assembly
1
1
1
1
1
2
1
1
1
1
0.35
1.30
1.80
0.00
0.20
2.00
0.00
17.80
16.50
44.00
1
1
1
1
1
22
6
2
2
1
4
0.00
0.00
0.00
0.00
0.01
0.00
0.33
0.25
0.13
0.00
0.00
Spare parts
B16
B19.1
B19.2
B22.1
B22.2
P03
P04
P08
P39
W18
W19
SA953171
Z3014475
Z30142617
SA955005
SA953325
PD720097-SS
PD760040-FZV
PD720015-FZV
PDCA43-2FZV
SA981223
PD720040-FZV
26172301000
O-ring
Lipseal
Lipseal
V-ring
V-ring
Shim set
Case bolt
Casing nut
Spacer
O-ring
Back liner bolt
Edition 1
JAN
06-W29
Spare parts
1/1
Slurry Pump
10.6
Toolkit
10.6.1
Standard tools
In addition to the special tools detailed in sub-section 9.3 and Table 10.6-2, and
installation tools and equipment detailed in sub-section 6.3, Table 10.6-1 lists a basic
toolkit for performing normal maintenance operations on the pump. A dial test indicator
may also be required to set bearing clearances – verify by reference to section 9.5.5.
Additional tools may also be listed in the motor installation and maintenance
documentation. Refer to Reference Publications, sub-section 11.2.
Table 10.6-1 Toolkit
Item Qty.
Type
1
1
Spanner AF (mm)
2
1
Socket AF (mm)
3
1
Torque wrench (Nm
range)
4
1
Adjustable spanner
(mm)
10.6.2
Sizes
HM50 HM75
HM100
HM150
HM200
HM250
HM300
19
22
24
30
36
36
24, 30,
36
19, 30,
36, 46
24, 30,
36, 55
17, 24
17, 19, 22, 24,
24,27, 30, 32,
30
36
10 - 300
25
20 - 500
30
40
Special tools
Table 10.6-2 Special tools
Item
Size
Part No.
Crank
1
HM50,
HM75
SA500244-M1
2
HM100
SA219594-M1
3
HM150
SA219595-M1
4
HM200
SA219596-M1
5
HM250
SA219598-M1
6
HM300
SA219598-M1
WH26HM1AAA0EN_03C.DOC
Packing
extractor
Back-liner lifter
Shaft extension
981865
N/A
N/A
SA501470-M1
981607
SA501471-M1
SA501472-M1
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04-W08
Spare parts
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Slurry Pump
11
APPENDICES
11.1
Torque table
The following table gives the recommended torque values for tightening bolts and screws.
NOTE: ALL TORQUE VALUE TOLERANCES ARE
±5%.
TORQUE VALUES (Nm)
HM50
HM75
HM100
HM150
HM200
HM250
HM300
Case bolt (P4)
147
147
163
189
189
270
370
Casing clamp screw (P9)
147
147
163
189
189
270
370
Bearing frame screw (P11)
163
163
163
177
189
338
370
Back-liner bolts (W19)
34
34
34
54
98
142
142
Housing clamp screws (P16)
34
34
40
54
67
80
80
16 to 18
26 to 34
26 to 34
26 to 34
ITEM
Tension screws (P23)
16 to 18 16 to 18 16 to 18
Saddle screws (P20)
34
34
40
54
54
108
142
End-cover bolt (B5)
34
34
40
40
54
81
126
Outlet flange half-clamp
bolts NP16
(F3)
20(M8) 40(M10) 70(M12) 170(M16) 170(M16) 170(M16) 170(M16)
Inlet flange half-clamp bolts
NP16 (F1)
20(M8) 70(M12) 170(M16) 170(M16) 170(M16) 170(M16) 170(M16)
WH26HM1AAA0EN_03C.DOC
JAN
04-W08
Appendices
2/2
Slurry Pump
11.2
Reference publications
Thermosiphon System non-pressurised
WH26HM1AAA0EN_03C.DOC
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04-W08
Appendices
3/2
Slurry Seal
B= closed system (non-pressurised)
Option 5
Thermosiphon System non-pressurised
Double Seals & Single seals
Unit
Theromsiphon system
10l
Drawing number
142.12601.SE
Suitable
When mains water is not present and double seal or single seal with low quench is needed.
Or when a separate system is needed because of the process conditions.
This system shall operate non-pressurised.
Any leakage of the inner seal will be in to the thermosiphon system; therefore it’s important to
monitor the level in the tank. If increasing there is a leakage on the inner seal and product will
enter the system. If the level is decreasing there is leakage on the secondary seal to the
atmosphere.
There is only thermosiphon that makes circulation on the barrier, and therefore it is important
that the system is fitted minimum 1-2m vertically above the seal chamber.
Avoid connecting pipe work with sharp bends.
If level in the tank is below connection from seal to the tank, thermosiphon circulation will stop.
For water quality, pressures see assembly instructions for the seal.
Benefits
Simple open system in stainless steel to be used for low quenching including, sight glass, (see
drawing 142.12601.SE) that provides a reliable condition for the seal to
Work in. The system keeps the primary seal (primary seal is operating on product) clean and
protects the secondary seal from dry running. There is also a cooling effect that keeps the
temperature down.
Exclude reaction from the product with oxygen in the air.
The system can not be pressurised.
3.2
JAN
02-W17
Edition 5
6/14
Slurry Seal
3.2
JAN
02-W17
Edition 5
8/14
Slurry Pump
11.3
Item
-
Weights table
Description
Weight (kg)
Bare shaft pump
315
W1
Case
80
P14
Frame
86
B99
Bearing cylinder assembly
45
Back pull-out assembly
198
-
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04-W08
Appendices
1/1