Metso 25411801001/A5684 Operation & Maintenance Manual Download Page 1

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Operation & Maintenance Manual

The Orion Series of Horizontal Slurry Pumps

MM200 EHC-D

Pump No

4118

01001/A56

, 25

4118

01002/A56

Supplier / Order Nr

Metso Minerals (UK) Ltd. / 1

10546

Customer Name

Pigott Shaft Drilling Ltd.

2005-

11 ed 2005-12-13

Summary of Contents for 25411801001/A5684

Page 1: ...ce Manual The Orion Series of Horizontal Slurry Pumps MM200 EHC D Pump No 25411801001 A5684 25411801002 A5685 Supplier Order Nr Metso Minerals UK Ltd 110546 Customer Name Pigott Shaft Drilling Ltd 2005 11 11 ed 2005 12 13 ...

Page 2: ... 2 3 Design 2 4 Materials and maximum working pressures 2 5 Surface treatment 2 6 General arrangement 2 7 Performance curves 2 8 Certificates test results 3 HEALTH SAFETY 4 DESCRIPTION OF OPERATION 5 CONTROL SYSTEM 6 INSTALLATION 6 1 General 6 2 Foundation requirements 6 3 Installation tools and equipment 6 4 Installation procedure 6 5 Pipe connections pump sump 6 6 Shaft gland 6 7 Motor and opera...

Page 3: ...ng pump clearances 9 5 2 Hydraulic parts and frame removal and fitting 9 5 3 Shaft seal removal and refitting 9 5 4 Shaft and bearing assembly removal and fitting 9 5 5 Shaft and bearings disassembly and re assembly 9 5 6 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...

Page 4: ...n 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 sub...

Page 5: ...mbersome 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 ...

Page 6: ... 3 6 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 Turn shaft at least every month ...

Page 7: ...over 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 si...

Page 8: ...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 rap...

Page 9: ... 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...

Page 10: ...E POS 2 HORIZONTAL UNDERHAND DRIVE SHAFT TURNED DOWN TO 60 MM DRG CH4270 BRG CART PT NUMBER PDWB05102 EXPELLER RING H C WITH GREASE NIPPLE 150 TO 200 MM FLANGE ADAPTOR 500311 1 Painting MP15 Capacity m h Total head m Pump speed rpm Specific gravity kg l Input power kW Motor Special req Motor supplied by Customer Drive supplied by Customer Motor sheave Motor bushing Pump sheave Pump bushing V belts...

Page 11: ...ted below Metso Minerals Sala AB Norrängsgatan 2 Box 302 S 73325 SALA Tel 46 224 374 00 Sweden Fax 46 224 169 69 Metso Minerals Industries Inc P O Box 340 COLORADO SPRINGS CO 80901 621 South Sierra Madre 80903 Tel 1 719 471 3443 USA Fax 1 719 471 4469 Metso Minerals UK Limited Parkfield Road Rugby CV21 1QJ Tel 44 1788 532217 United Kingdom Fax 44 1788 575364 Please provide the following informatio...

Page 12: ... 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 delive...

Page 13: ...IONS ARE NOT OBSERVED The V belt guard must always be mounted during operation WARNING The sign is mounted on the V belt guard 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 The guard must always be ref...

Page 14: ...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 dow...

Page 15: ...llations 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 tightene...

Page 16: ...ial 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 ...

Page 17: ...LOUR 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 surf...

Page 18: ...25411801000 ...

Page 19: ...25411801000 ...

Page 20: ...phere 35 mm Impeller material Metal Liner material Metal H m 200 400 600 800 1000 20 40 60 80 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 r min BEL 60 70 75 75 78 78 80 80 70 4 00 m 6 00 m 8 00 m 10 00 m P kW Q m h 200 400 600 800 1000 25 50 75 100 125 150 175 Based on clear water tests correct for other conditions 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 ...

Page 21: ...ry Basic terminology methodology EN 292 2 Safety of machinery Technical principles and specifications EN 809 Pumps and pump units for liquids common safety requirements and furthermore declare that it is not permitted to put the slurry pump into service until the machinery into which it is to be incorporated has been found and declared to be in conformity with the provisions of Directive 98 37 EG ...

Page 22: ... 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 exi...

Page 23: ...y 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 DO NOT wear loose clothing when working in close proximity to rotating parts NEVER allow water or slurry to rise above the top of the pump base MAINTAINING THE PUMP SWITCH OFF and ISOLATE the electri...

Page 24: ...en 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 To obtain the be...

Page 25: ...re 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...

Page 26: ...4 3 5 6 Figure 4 3 2 Operating outside BEP At low load 3 Abrasion on the impeller vane s discharge side 4 Vortices occur on the vane s vacuum side 5 Vortices 6 Abrasion caused by particles striking and bouncing against the surface Impeller vane inlet Pump casing nose 7 8 9 10 Figure 4 3 3 Operating outside BEP On overloading 7 Vortices are formed on the discharge side of the impeller vane 8 Abrasi...

Page 27: ... 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 recircula...

Page 28: ...Slurry Pump WH14AAAAAA0EN_04D DOC JAN 04 W08 Control system 1 1 5 CONTROL SYSTEM NOT APPLICABLE ...

Page 29: ...tial 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 nee...

Page 30: ...ht 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 vic...

Page 31: ...IFTING THE PUMPSET INTO POSITION IS NOT CONVENIENT PREPARE A FOOTPRINT PATTERN OF THE BEDPLATE A3 USING HARDBOARD 1 2 3 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 fr...

Page 32: ...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...

Page 33: ...tes 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...

Page 34: ...LLOWABLE FLANGE FORCES PLEASE CONSULT METSO MINERALS SHOULD THE FLANGE LOAD REQUIREMENT BE GREATER C L Fy y M Fx M x z z M F 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...

Page 35: ...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 reinfor...

Page 36: ...vering 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 6 6 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 ...

Page 37: ...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 ASSE...

Page 38: ...fore 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...

Page 39: ...F 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 Descr...

Page 40: ...e 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 EQUIP...

Page 41: ...ect 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 Service Dri...

Page 42: ...peline 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 asse...

Page 43: ...E 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 ...

Page 44: ...king 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 ...

Page 45: ...al 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 ...

Page 46: ...in 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 ...

Page 47: ...ended 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 tem...

Page 48: ...g lubrication points See Figure 9 4 3 1 Part Position Qty cc Frequency Lubricant Bearing cylinder A See Table 9 4 2 1 See Table 9 4 2 1 SKF LGMT3 or equivalent see Table 9 4 1 1 Motor and or gearbox where applicable See manufacturer s instruction manual A Figure 9 4 3 1 Lubrication point diagram Bearing greasing points A ...

Page 49: ...his 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...

Page 50: ...an 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...

Page 51: ...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 ca...

Page 52: ...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...

Page 53: ...crews 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 5 Opening the pump Front Pull Out Method a Disconnect the inlet and outlet pipework from the pump NOTE METAL PUMPS ARE EQUI...

Page 54: ... 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 ...

Page 55: ...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 ba...

Page 56: ...ack 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 F...

Page 57: ...ting iii Impeller Release Mechanism IRM type 1 An IRM a is fitted behind the shaft sleeve b to ease removal of the impeller during maintenance and repair Removing this mechanism releases the tightening torque on the impeller See Figure 9 5 2 i Figure 9 5 2 i Using impeller release mechanism typical eases impeller removal ...

Page 58: ...clamping bolt This should make it spring open To assemble IRM B25 1 apply an anti seize compound to the IRM assembly screw threads 2 ensure that the IRM clamping bolt is tightened up and that IRM B25 and impeller spacer B54 fit together correctly i e as cone and cup G2 G25 G54 Figure 9 5 2 ii Impeller Release Mechanism removal ...

Page 59: ...Slurry Pump WH18HYDAAA0EN_01D DOC JAN 04 W08 Care and maintenance 1 1 9 5 2 Hydraulic parts and frame dismantling and fitting iv Hydraulic system Not applicable ...

Page 60: ... nipple G21 is provided to lubricate the packing Expeller ring G7 locates in bearing frame P14 inner flange and is retained in position by back liner W4 Differential impellers of reduced diameter may be used in some installations to give an improved gland seal where the expeller operation would otherwise be marginal 1 Running Checks During pump operation there should be no leakage from the gland I...

Page 61: ...dically lubricate the gland through grease nipple G21 NOTE THE AMOUNT OF GREASE INJECTED SHOULD BE A QUARTER OF THE QUANTITY INJECTED INTO THE MAIN BEARINGS AND AT THE SAME PERIODICITY AS THE MAIN BEARINGS SEE LUBRICATION SECTION 9 4 THE PERIODICITY AND QUANTITY GIVEN HERE ARE A GUIDE AND SHOULD BE MODIFIED IN LIGHT OF OPERATIONAL EXPERIENCE Figure 9 5 3 1 Arrangement of packing rings showing dire...

Page 62: ...s to expeller ring G7 and gland by opening up the pump using the Front or Back Pull Out Method b Remove expeller G15 c Slide expeller ring G7 complete with the gland seal assembly from the shaft 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 d Remove shaft sleeve G2 and gaskets G58 if these items ha...

Page 63: ... listed fit the following parts over shaft sleeve G2 into the bore of expeller ring G7 One turn of packing G5 Lantern ring G1 Two rings of packing G5 Gland follower G10 e Fit gland follower screws G18 and nip finger tight f Using the wet end sealing system drawing in section 10 4 identify and fit the appropriate gaskets and spacers onto the shaft in the order shown g Offer up the expeller ring and...

Page 64: ...he 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 2 Re fitting a Cl...

Page 65: ...are and maintenance 2 2 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 ...

Page 66: ... 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 c...

Page 67: ...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 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 ...

Page 68: ... 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...

Page 69: ... 5 1 A B D C E E 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 ...

Page 70: ...ity 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 out...

Page 71: ...Slurry Pump WH21AAAD000EN_03B DOC JAN 04 W08 Care and maintenance 1 1 9 5 6 Pump drive removal and re fitting NOT APPLICABLE ...

Page 72: ...ONTACT METSO MINERALS FOR FURTHER ADVICE 9 6 2 Pump fails to start Is power supply live No Check that Yes 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 Can pump be started manually No Is there a fault with Yes level control equipment other monitoring or con...

Page 73: ...d try to rotate the 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 Dismantle the drive and check that both the motor and pump shaft can be rotated Fit new bearings if necessary See section 9 5 and the motor manufacturer s instructions Check that pump clearances are correct See section 9 5 1 9 6 4 The pump is running but th...

Page 74: ...s Either adjust the feed to the pump or adjust the rating of the drive motor and pump to suit the operating conditions Are all valves open and are the pipes clear Yes No Remedy the fault Is the impeller clogged No 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 ...

Page 75: ...r W3 Back liner W4 Shaft sleeve G2 Gland packing G5 Expeller ring G7 Expeller G15 Bearing cylinder assembly B99 Set of seals B98 10 2 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 Approxim...

Page 76: ...Slurry Pump WH24AAAAAA0EN_03B DOC JAN 04 W08 Spare parts 1 1 10 4 Spare part drawing ...

Page 77: ...Slurry Pump WH24AM1W010XX_02E DOC JAN 04 W08 Spare parts 1 1 W3 W2 W4 W1 W6 F3 F4 F1 F2 W17 W19 W20 W21 W18 ...

Page 78: ...Slurry Pump WH24AM1G410XX_03B DOC JAN 04 W08 Spare parts 1 1 FR250 FR300 G2 G58 B25 B54 FR400 FR500 FR600 FR750 i G2 G58 G20 ii V G10 G2 G58 G19 G18 G7 G5 G15 G21 G1 G17 1 ...

Page 79: ...Slurry Pump WH24AA1B012XX_04B DOC JAN 04 W08 Spare parts 1 1 BSP A A A A B13 B22 2 B11 B10 B19 2 B2 2 B5 B3 B14 B19 1 B2 1 B1 B6 B16 B22 1 B8 B54 B25 G58 ...

Page 80: ...Slurry Pump WH24AA1F010XX_01B DOC JAN 04 W08 Spare parts 1 1 P3 P23 P22 P24 P21 P19 P38 P20 P28 P17 P18 P29 P15 P16 P14 P11 P12 P13 P30 P31 P32 P10 P5 P2 P1 P4 P2 P1 V P1 P39 P6 P9 P39 P8 P34 P35 P1 P8 ...

Page 81: ...D730099 Flinger 1 0 50 B02 1 PDCH1875 End cover 1 2 40 B02 2 PDCH3075 End cover 1 2 70 B03 PD730025 Shim set 1 2 58 B06 PDCB821 Shaft spacer 1 0 33 B08 Z0370438 Bearing 2 3 90 B10 SA899018 100 Key 1 0 15 B11 PDCH4270 Shaft 1 25 80 B14 PD730004 Bearing cylinder housing 1 28 50 B98 PDWB05 S1 Set of seals 1 0 00 B99 PDWB05102 Bearing shaft assembly 1 76 00 Spare parts B25 PDCH6558 Impeller release me...

Page 82: ...or installation and maintenance documentation Refer to Reference Publications sub section 11 2 Table 10 6 1 Toolkit Item Qty Type Sizes MM100 MM150 MM200 MM250 MM300 MM350 MM 400 1 1 Spanner AF mm 19 22 24 30 36 36 2 1 Socket AF mm 17 24 17 19 24 27 30 22 24 30 36 24 30 36 19 30 36 46 24 30 36 46 55 3 1 Torque wrench Nm range 10 300 20 500 4 1 Adjustable spanner mm 25 30 40 10 6 2 Special tools Ta...

Page 83: ...89 189 270 270 Casing clamp screw P9 147 163 189 189 270 270 Bearing frame screw P11 163 163 177 189 338 338 Back liner bolts W19 34 34 54 98 142 142 Housing clamp screws P16 34 40 54 67 80 80 Tension screws P23 16 to 18 16 to 18 16 to 18 26 to 34 26 to 34 26 to 34 Saddle screws P20 34 40 54 54 108 108 End cover screw B5 34 40 40 54 81 81 Outlet flange half clamp bolts NP16 F3 M8 20 M10 40 M12 70 ...

Page 84: ...Slurry Pump WH26MM1AAA0EN_03C DOC JAN 04 W08 Appendices 3 2 11 2 Reference publications ...

Page 85: ...12000EN_03B DOC JAN 04 W08 Appendices 1 1 11 3 Weights table Item Description Weight kg Bare shaft pump 632 W1 Case 190 P14 Frame 152 W3 Impeller 55 B99 Bearing cylinder assembly 76 Back pull out assembly 352 P13 Base 70 ...

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