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Weir WARMAN AH Installation, Operation & Maintenance Manual

Centrifugal slurry pumps
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WARMAN
Centrifugal Slurry Pumps
AH Pumps
Installation, Operation, & Maintenance Manual
Copyright © 2015, Weir Minerals Australia Ltd.
Warman
is a registered trademark of Weir Minerals Australia Ltd
Weir Minerals Australia Ltd. ("the Company") is the owner of the copyright and all confidential information in
this document. The document may contain information that is private, confidential and/or privileged. The
document must not be copied in whole or in part, in any form or by any means, and the information in it must
not be disclosed to any person, or used for any purpose other than the specific purpose for which it has been
provided, without the prior written consent of the Company.
Document Name: IOM-WARMAN-AH-EN USER
Document No: DOC-04-00048
®
User Manual
UNCONTROLLED DOCUMENT
Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved.
.
Page I - 0
3/Apr/15 Rev 2.0

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Summary of Contents for Weir WARMAN AH

  • Page 1 Weir Minerals Australia Ltd Weir Minerals Australia Ltd. (“the Company”) is the owner of the copyright and all confidential information in this document. The document may contain information that is private, confidential and/or privileged. The...
  • Page 2 Installation, Operation, & Maintenance Manual Project Information, Certification and other Relevant Manuals / Reference Material UNCONTROLLED DOCUMENT Page I - i Document Name: IOM-WARMAN-AH-EN USER 3/Apr/15 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 3: Revision Page

    Apr 3, 2015 Safety notes improved. All Jon Waite sections at Rev 2.0 Nestor Cinotti UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 0 - ii Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 4: Table Of Contents

    Pump Part Identification ......................4-3 Bearing Power Requirements ........................4-3 Tightening Torques ............................4-4 Materials ..............................4-5 UNCONTROLLED DOCUMENT Page 0 - iii Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 5 Effects of Unrestricted Runback and Reverse Rotation ............. 7-7 Motor Rotation Check (Jog Test) ......................... 7-7 Gland Seal ..............................7-9 UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 0 - iv Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 6 Repacking Gland ........................9-3 9.3.3 Tightening Nuts and Bolts......................9-4 9.3.4 Labyrinth Grease Purging......................9-4 UNCONTROLLED DOCUMENT Page 0 - v Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 7 10.5.2.1 Service Intervals ........................10-13 10.5.2.2 Quantity of Oil......................... 10-13 10.5.3 Recommended Lubricants...................... 10-14 UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 0 - vi Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 8 Multi-element Pump Commissioning ..................14-10 14.3.4 Pump Commissioning Sheet ....................14-15 14.4 Spare Parts .............................. 14-17 UNCONTROLLED DOCUMENT Page 0 - vii Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 9 Figure 13-4: Shaft Wrench ............................13-3 Figure 14-1: Pump with Gear Box Housings ......................14-16 UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 0 - xii Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 10 Table 12-1: Troubleshooting Packed Gland Seal Problems..................12-2 Table 12-2: Troubleshooting Mechanical Seal Problems .................... 12-3 UNCONTROLLED DOCUMENT Page 0 - xvii Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 11 Table 12-3: Fault Finding Sheet ..........................12-5 Table 13-1: List of Special Tools..........................13-1 UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 0 - xviii Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 12: Introduction

    Warman AH pumps are range of horizontal slurry pumps and are used for difficult mill duties. A wide variety of impellers and shaft seals used in AH pumps provide a perfect fit for multiple applications.

  • Page 13: Overview Of The Manual

    Chapter Description Introduction Contains an introduction to the Warman AH pumps and the scope of the manual. Lists the safety guidelines that must be adhered to while installing, operating and  Safety maintaining the pump.

  • Page 14: Glossary Of Abbreviation

    Room Temperature Vulcanizing Safety Data Sheets Total Dissolved Solids Table 1-2: Abbreviations UNCONTROLLED DOCUMENT Page 1 - 3 Glossary of Abbreviation Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 15: Safety

    Important Information EXPLOSION • Weir Minerals would like to bring to your attention the potential hazard caused by the continued operation of centrifugal pumps when the intake and discharge are blocked. • Extreme heat is generated leading to vaporisation of the entrapped liquid. This can result in a life threatening explosion if operation is continued.
  • Page 16 • Suitable pressure relief must be included in the pipe work. UNCONTROLLED DOCUMENT Page 2 - 2 Important Information Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 17 RTV silicon to protect the thread of the holes for further use. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 2 - 3 Important Information Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 18: Operating Conditions

    • Assess the risks associated with lifting a used pump before lifting it. FAILURE DUE TO CASTING REPAIRS Castings made from A series Weir Minerals materials, for example, A05, A61, etc. are brittle and have low thermal shock resistance. Attempts to repair or rebuild by welding causes catastrophic failure.

  • Page 19: Efficient Use And Intended Use

    The pumps must not be operated beyond the allowable limits of pressure, temperature and speed specified for the application. These limits are dependent on the pump type, configuration and materials used. If there is any doubt about the suitability of the product for the intended application, contact Weir Minerals, quoting the serial number.

  • Page 20: Safe Working On Pumps

    Personnel injury or illness may result from contact with rotating parts, seal leakage or spray from the rotating shaft. UNCONTROLLED DOCUMENT Page 2 - 6 Safe Working on Pumps Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 21: Gland Adjustment

    After an emergency, stop and check for blockages and then follow the commissioning procedure. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 2 - 7 Fire Fighting Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 22: Transport And Storage

    • Minimises the risk of injury to all personnel involved in the freight transportation. • Minimises the risk of damage to the freight. UNCONTROLLED DOCUMENT Page 3 - 1 Transportation Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 23: Chain Of Responsibility

    • Strong cornering to avoid an obstacle • Bad road or weather conditions UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 3 - 2 Transportation Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 24: Load Restraint Tools

    • Do not use ropes or over-centre load chain binders (dogs) (refer to Figure 3-2 on page 3-3), when you secure loads for collection or delivery from Weir Minerals Division. Figure 3-2: Over-centre Load Chain Binder INJURY WHILE LASHING/UNLASHING The use of over-centre load chain binders (dogs) results in the release of the stored energy in the load restraint tools while unlashing.

  • Page 25: Figure 3-3: Attach Shaft Clamp

    Fix the set screw in the handle of the clamp hard against the pump base to lock the bearings. 001. Set Screw 315. Shaft Clamp Figure 3-4: Fix Set Screw UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 3 - 4 Transportation Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 26: Tie-Down Instructions

    It is possible for operational and storage problems to arise due to environmental conditions the pump is subjected to. These problems must be corrected at the owner’s expense prior to operation. Weir Minerals will accept no responsibility for these problems. These provisions are applicable to Weir Minerals proprietary items only. For the appropriate storage procedures for non-Weir Minerals items refer to specific requirements from the manufacturer.

  • Page 27: Maintenance Schedule

    To store the pumps for prolonged periods: • Weir Minerals recommends to drain the oil filled assemblies (Oil Filled Bearing Assembly - K and KH) leaving some oil in to cover the lowest bearing rollers. This procedure helps to prevent the following two risks: •...

  • Page 28: Hazardous Chemicals

    21. Apply paint on any damaged paint surfaces. Also, note the following: UNCONTROLLED DOCUMENT Page 3 - 7 Storage Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 29: Long-Term Storage

    Failure to follow this advice will void the warranty issued by Weir Minerals. NON-WEIR WARMAN ITEMS These provisions are applicable to Weir Warman proprietary items only. For the appropriate storage procedures for non-Weir Warman items, refer to specific requirements from the manufacturer.

  • Page 30: Technical Data

    1.5/1 1.5/1 B-AH 10/8 GYFC 10/8 GYFC-AH Table 4-1: Pump Identification Code UNCONTROLLED DOCUMENT Page 4 - 1 Pump Identification Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 31: Discharge Positions

    Medium 6/4 - 10/8 Large 12/10 upwards Table 4-4: Pump Size Grouping UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 4 - 2 Pump Identification Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 32: Pump Part Identification

    Table 4-5 on page 4-3 Table 4-6 on page 4-4 are for reference only. Sometimes, power exceeds the limit. Consult your local Weir Minerals Engineering team, when the power exceeds the limit. Table 4-5 on page 4-3 provides the power rating of the basic bearing assembly.

  • Page 33: Tightening Torques

    Recommended Torque (± 10%) (Nm) 1,200 1,500 Table 4-8: Torque Settings for Metric Bolts UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 4 - 4 Tightening Torques Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 34: Materials

    Warman slurry pumps. For any assistance with the selection of specific material, consult your local Weir Minerals representative. PUMP WEAR IS AFFECTED BY SLURRY PROPERTIES Large variations in slurry properties, increases the rate of wear and corrosion of pump components.

  • Page 35: Table 4-11: Material Types

    Polyurethane Elastomers Y Series Ceramics Z Series Composite Materials Coatings Table 4-11: Material Types UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 4 - 6 Materials Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 36: Description

    • The centrifugal pump operates by increasing pressure from the inlet (lower pressure) to the outlet (higher pressure). UNCONTROLLED DOCUMENT Page 5 - 1 Introduction to AH Pump Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 37: Figure 5-1: Basic Pump

    044. Gland Assembly 075. Shaft Sleeve 111. Packing Figure 5-1: Basic Pump UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 5 - 2 Introduction to AH Pump Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 38: Pump Component Description

    Base Plate Base Plate Motor Support Figure 5-2: Examples of Drive Configurations UNCONTROLLED DOCUMENT Page 5 - 3 Pump Component Description Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 39: Bearing Assemblies And Frames

    Oil Filled Bearing Assembly - Difference between K and KH Assemblies Oil lubricated and grease lubricated bearing assemblies use different components.. OIL FILLED ASSEMBLY Contact your local Weir Minerals representative for any assistance with oil filled assemblies. Type K • Oil filled for submerged applications where the surrounding fluid keeps the bearing assembly at a safe working temperature.

  • Page 40: Liners

    20/18 AH Table 5-2: Standard Pump Liner Fit-up (regardless of frame) UNCONTROLLED DOCUMENT Page 5 - 5 Pump Component Description Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 41: Installation

    • Medium pumps: 3 m all around including above • Large pumps: 4 m all around including above UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 6 - 1 Installation Safety Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 42: Foundations

    Align and Grout the Warman Baseplates BASEPLATES Contact your local Weir Minerals representative for more information on fixing baseplates. ALIGN AND GROUT THE WARMAN BASEPLATES • The initial mounting, that is, the plinth is generally formed 50 mm larger all round than the respective baseplate.

  • Page 43: Mount The Pump Base On A Steel Framework

    Mount the Pump Base on a Steel Framework BASEPLATES Contact your local Weir Minerals representative for further information on fixing baseplates. To mount the pump base directly on a steel framework: 1. Design a frame of sufficient strength to withstand normal pumping operational stress.

  • Page 44: Shaft Alignment

    ALIGNMENT, TENSIONING, AND ADJUSTMENT OF VEE-BELT DRIVES The following is recommended as a basis for alignment, tensioning, and adjustment of  vee-belt drives. Contact your local Weir Minerals representative or belt supplier for further information on a specific product. For optimum performance of vee-belts: •...

  • Page 45: Alignment

    2. Apply a force at right angle to the belt at the centre of the span which is sufficient to deflect one belt by 16 mm per metre of span. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 6 - 5 Pump Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 46: Adjustment

    • A drive run for approximately two hours. Check the drive subsequently, at regular maintenance intervals. UNCONTROLLED DOCUMENT Page 6 - 6 Pump Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 47: Alignment Of Direct-Coupled Pumps

    The following is recommended as a basis for alignment of direct-coupled pumps. Contact your local Weir Minerals representative for more information on a specific product. In a direct-coupled drive, misalignment causes unnecessary vibration and wear on the bearings. Avoid rigid couplings (that is, couplings that bolt directly together without any flexible member in between) and do not use them without consultation with Weir Minerals Division.

  • Page 48: Angular Shaft Alignment

    • Not to exceed 0.1 mm on dial indicator (that is, 0.05 mm eccentricity) UNCONTROLLED DOCUMENT Page 6 - 8 Pump Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 49: Pipework

    • Ensure all pipe designs are on the basis of zero pump flange loading. If this condition cannot be achieved, consult your local Weir Minerals representative to obtain values for the maximum allowable external loads and moments on the pump flanges.

  • Page 50: Flanges

    Warman pump flanges. Alternatively, check if actual loads and moments are within the allowable values by submitting the actual values to your local Weir representative for comparison against the allowable values. Units •...

  • Page 51: Figure 6-10: Flange Loading

    = About any axis in x-z plane through B. Acts parallel and level with flange face UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 6 - 11 Pump Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 52 • High process slurry temperatures cause thermal expansion in the pipes which results in high thrust loads on the pump. In these cases consult your local Weir Minerals representative. LOADS AND MOMENTS •...

  • Page 53: Table 6-2: Allowable Loads On Flanges

    • Ensure that pipes are aligned with the pump flanges and supported independent of the pump and as close to the pump as practical. Use approximate Warman joint rings at the pump flanges. • All allowable loads and moments can act concurrently. Consult your local Weir Minerals representative for the following: •...

  • Page 54: Intake Conditions

    • Header tank 2 for inter-seal oil volume. UNCONTROLLED DOCUMENT Page 6 - 14 Oil Filled Bearing Assembly - K and KH Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 55: Ffks005-1 With Single (Full) Duo-Cone Seal

    In submerged operation, it is recommended to use automated greasing units instead of the grease nipples provided. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 6 - 15 Oil Filled Bearing Assembly - K and KH Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 56: Commissioning

    TAPER LOCK Check taper lock tension after first 3 hours of operation. UNCONTROLLED DOCUMENT Page 7 - 1 Commissioning Safety Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 57: Commissioning Steps

    Rotate the shaft manually in clockwise direction using the shaft clamp. This ensures that the impeller turns without any restriction within the pump. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 2 Commissioning Steps Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 58: Figure 7-2: Rotate Shaft Clamp

    For impeller checking and readjustment procedure, refer “Impeller Adjustment” on page 7-14. 5. Pipework UNCONTROLLED DOCUMENT Page 7 - 3 Commissioning Steps Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 59: Gland Adjustment

    Check and adjust gland leakage as required. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 4 Commissioning Steps Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 60: Avoidance Of Impeller Loosening - Runback And Reverse Rotation

    The correct rotation of the pump is displayed by a cast arrow on the front of the pump casing as shown in Figure 7-4 on page 7-6. UNCONTROLLED DOCUMENT Page 7 - 5 Commissioning Steps Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 61: Incorrect Direction Of Rotation And Input Torque Via Pump Shaft

    1. Magnetic brake to prevent any rotation of the pump and motor when the electrical power is disconnected from the motor. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 6 Commissioning Steps Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 62: Effects Of Unrestricted Runback And Reverse Rotation

    STATIC HEAD For any proposed application where the system static head exceeds 50 m and the length of the discharge pipeline exceeds 200 m, contact your local Weir Minerals representative for specific advice regarding precautions required to avoid these problems.
  • Page 63 12. De-isolate the drive unit from the power supply. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 8 Motor Rotation Check (Jog Test) Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 64: Gland Seal

    067. Neck Ring 118. Lantern Restrictor Figure 7-6: Example of Some Gland Seal Arrangements UNCONTROLLED DOCUMENT Page 7 - 9 Gland Seal Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 65: Gsw Flow And Pressure Requirements

    Pumps fitted with impeller release collars have the potential to act as large cutters. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 10 Gland Seal Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 66: Gsw Control Devices

    6.5 - 8.0. Solids Content • Dissolved - 1,000 ppm (mg/L) UNCONTROLLED DOCUMENT Page 7 - 11 Gland Seal Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 67: Hs Centrifugal Seal

    Centrifugal seals will fail if operated outside their allowable limits of inlet head and pump speed. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 12 HS Centrifugal Seal Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 68: Figure 7-7: Type Hs Centrifugal Seal Assembly

    032. Frame Plate 111. Packing Figure 7-8: Warman Pump with HS Components UNCONTROLLED DOCUMENT Page 7 - 13 HS Centrifugal Seal Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 69: Mechanical Seal

    Clearance between Impeller and Throatbush c. Front Nut Figure 7-9: Impeller Adjustment UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 14 Mechanical Seal Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 70: Table 7-3: Bearing Housing Clamp Bolt Torque

    G, GG U, UV 1,500 1,500 Table 7-3: Bearing Housing Clamp Bolt Torque UNCONTROLLED DOCUMENT Page 7 - 15 Impeller Adjustment Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 71: Tightening Nuts And Bolts

    6 months or 2,000 hours of operation. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 7 - 16 Tightening Nuts and Bolts Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 72: Operation

    MONITOR PUMP PERFORMANCE Lack of monitoring temperature, flow, pressure, and vibration can lead to catastrophic failure of the pumps. Weir Minerals recommends following ISO standards. LARGE SIZED PUMPS The operation and maintenance of the large pumps has an increased risk due to the size and weights of components as well as the physical size of the complete pump unit.

  • Page 73: Shaft Seal

    Slacken off gland and adjust it so that a small flow is obtained along the shaft. Note that pumps supplied directly from Weir Minerals factories usually have tight glands to minimise shaft vibration during transport. For centrifugally sealed pumps, screw the grease cup down a few turns to charge the static seal chamber with grease.

  • Page 74: Normal Pump Start-Up

    UNCONTROLLED DOCUMENT Page 8 - 3 Normal Pump Start-up Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 75: Abnormal Start-Up

    • High suction lift causes air intake through the gland. Inspection of the gland will reveal above faults. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 8 - 4 Abnormal Start-up Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 76: Operating Faults

    Such UNCONTROLLED DOCUMENT Page 8 - 5 Operating Faults Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 77: Pump Shut Down

    For recommended maximum allowable pump speeds, refer to the specific pump performance curve which takes into consideration the impeller and liner materials and the maximum allowable peripheral velocity. Contact your local Weir Minerals representative for maximum bearing and impeller tip speeds. MAXIMUM ALLOWABLE PUMP SPEEDS...

  • Page 78: Impeller Adjustment

    Select materials according to the following tabulated recommendations. e. Some stuffing boxes and expeller rings have been upgraded from the normal 700 kPa rating to the maximum allowable working pressure of the pump. Contact your local Weir Minerals representative for more information on availability and suitability.

  • Page 79: Table 8-1: Series A Slurry Pumps (Type Ah)

    2. Use mild steel (E02, E03 & E05) Cover Plate Bolts (015) for test pressures below 2,000 kPa and high tensile steel bolts (E47 & E48) for pressure above 2,000 kPa and/or for the Cover Plate Bolt at the Cutwater. Table 8-1: Series A Slurry Pumps (type AH) UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 8 - 8 Maximum Allowable Pressures Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 80: Bearing Fault Frequencies For Conditioning Monitoring

    • Non-standard cover plate bolt materials, example C23 Stainless Steel - refer to your local Weir representative in this special case. 8.12 Bearing Fault Frequencies for Conditioning Monitoring Contact your local Weir Minerals representative for bearing fault frequencies for conditioning monitoring figures. 8.13 Oil Filled Bearing Assembly - K and KH...

  • Page 81: 8.13.2.1 Operation Maintenance

    UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 8 - 10 Oil Filled Bearing Assembly - K and KH Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 82: Maintenance

    • Drain the pump and isolate pipework before dismantling the pump. The appropriate safety precautions must be taken where the pumped liquids are hazardous. UNCONTROLLED DOCUMENT Page 9 - 1 Maintenance Safety Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 83: Maintenance Check Points

    • Tightening nuts and bolts • Labyrinth grease purging • Bearing assembly lubrication UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 9 - 2 Maintenance Check Points Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 84: Gland Adjustment

    1. Remove the gland bolts and gland clamp bolts and the two halves of the gland follower from the pump. 2. Remove the old packing. UNCONTROLLED DOCUMENT Page 9 - 3 Running Maintenance Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 85: Tightening Nuts And Bolts

    (impeller and liners). UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 9 - 4 Overhaul Maintenance Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 86: Pump Disassembly

    UNCONTROLLED DOCUMENT Page 9 - 5 Overhaul Maintenance Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 87 A complete new bearing assembly at one end of a bearing assembly may be installed with a used bearing assembly at the other if required. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 9 - 6 Overhaul Maintenance Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 88 UNCONTROLLED DOCUMENT Page 9 - 7 Overhaul Maintenance Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 89 As wear occurs, the face widens towards the inner diameter. Always replace seals as pairs. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 9 - 8 Overhaul Maintenance Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 90 Lubrication Specification for Heavy Duty, Basic and Modified Basic Bearing Assemblies LUBRICATION • This section provides the general recommended information only. • Contact your local Weir Minerals representative for any assistance. This section describes: • Recommended bearing grease specification for Heavy Duty, Basic and Modified Basic Bearing Assemblies •...

  • Page 91: Table 10-1: Recommended Bearing Grease Characteristics

    Basic Bearing Assemblies - Initial Grease Fill Quantities Table 10-3: UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 2 Lubrication Specification for Heavy Duty, Basic and Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 92 Bearings must never be over greased. UNCONTROLLED DOCUMENT Page 10 - 3 Lubrication Specification for Heavy Duty, Basic and Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 93 10-6 and Table 10-7 on page 10-7). Use only recommended, clean grease. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 4 Lubrication Specification for Heavy Duty, Basic and Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 94: Table 10-5: Lubrication Intervals - Heavy Duty Bearing Assembly

    Lubrication Intervals - Heavy Duty Bearing Assembly Table 10-5: UNCONTROLLED DOCUMENT Page 10 - 5 Lubrication Specification for Heavy Duty, Basic and Modified Basic Bearing Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 95: Table 10-6: Lubrication Intervals - Basic Bearing Assembly

    Table 10-6: Lubrication Intervals - Basic Bearing Assembly UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 6 Lubrication Specification for Heavy Duty, Basic and Modified Basic Bearing Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 96: Table 10-7: Lubrication Intervals - Modified Basic Bearing Assemblies

    Table 10-7: Lubrication Intervals - Modified Basic Bearing Assemblies UNCONTROLLED DOCUMENT Page 10 - 7 Lubrication Specification for Heavy Duty, Basic and Modified Basic Bearing Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 97 (three months capacity on smaller frames and one month capacity on the larger frames). UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 8 Lubrication Specification for Heavy Duty, Basic and Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 98: Table 10-8: Grease Quantities For Labyrinth Grease Purging

    85 C or higher. UNCONTROLLED DOCUMENT Page 10 - 9 Lubrication Specification for Modified Basic Bearing Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 99: Figure 10-2: Thrust Rib

    Grease Brand Type ® Mobilith SHC 220. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 10 Lubrication Specification for Modified Basic Bearing Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 100: Figure 10-3: Components And Disposition Of Grease In Ffx Bearing Assembly With Single Drive-End Bearing

    HGK005M, HGK205M, and TK005-1M bearing assemblies. UNCONTROLLED DOCUMENT Page 10 - 11 Oil Filled Bearing Assembly - K and KH Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 101: Table 10-9: Lubricant Specifications - Hgk005M, Hgk205M And Tk005-1M

    In this case, check at regular intervals that it has not fully discharged. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 12 Oil Lubricated Bearing Assembly - Y Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 102: Table 10-12: Oil Service Intervals

    EAMY005 0.80 UY005M FAMY005 Table 10-13: Oil Quantities UNCONTROLLED DOCUMENT Page 10 - 13 Oil Lubricated Bearing Assembly - Y Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 103: Recommended Lubricants

    The grease for the centrifugally sealed pump static seal chamber must have the specifications as per Table 10-1 on page 10-2. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 10 - 14 Centrifugally Sealed Pump Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 104: Decommissioning And Disposal

    During decommissioning, ensure that the pump components are secured properly, so that they do not fall or tip over, or cause injury. UNCONTROLLED DOCUMENT Page 11 - 1 Decommissioning Safety Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 105: Hazardous Chemicals

    Correct PPE must be worn when disassembling pumps. 11.2 Decommissioning To decommission the slurry pumps, Weir Minerals recommends the following steps: 1. Flush the pump with clean water. a. For small to medium pumps, flush the pump for 10 to 15 minutes.
  • Page 106 Follow the above procedure to make the pump ready for selling or disposal. UNCONTROLLED DOCUMENT Page 11 - 3 Decommissioning Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 107 Disposal When a pump is sold, all pump documentation and guarding must be supplied with it. To dispose of a complete pump unit, Weir Minerals recommends the following steps: 1. Confirm the hazards associated with the slurry last pumped. 2. Ensure that all lifting points are suitable to use.

  • Page 108: Troubleshooting

    • The leakage of saline GSW from the gland must be trapped and converted to waste to avoid corrosion of the pump base and other components. UNCONTROLLED DOCUMENT Page 12 - 1 Packed Gland Seal Problems Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 109: Table 12-1: Troubleshooting Packed Gland Seal Problems

    • Worn out packing. Table 12-1: Troubleshooting Packed Gland Seal Problems UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 12 - 2 Packed Gland Seal Problems Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 110: Table 12-2: Troubleshooting Mechanical Seal Problems

    • It is recommended to use impellers without backvanes for mechanical seals to reduce the flow and turbulence wear in the seal chamber. UNCONTROLLED DOCUMENT Page 12 - 3 Mechanical Seal Problems Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 111 Troubleshooting 12.3 Bearing and Impeller Tip Speeds Contact your local Weir Minerals representative for maximum bearing and impeller tip speeds. MAXIMUM ALLOWABLE PUMP SPEEDS For recommended maximum allowable pump speeds, refer to the specific pump performance curve which takes into consideration the impeller and liner materials and the maximum allowable peripheral velocity.
  • Page 112 Inlet pipe diameter too small or length of inlet pipe too long Table 12-3: Fault Finding Sheet UNCONTROLLED DOCUMENT Page 12 - 5 Fault Finding Chart Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 113 Rotating part rubbing on stationary part Bearings worn Table 12-3: Fault Finding Sheet (Continued) UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 12 - 6 Fault Finding Chart Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 114 Excessive clearance at bottom of stuffing box, forcing packing into pump Table 12-3: Fault Finding Sheet (Continued) UNCONTROLLED DOCUMENT Page 12 - 7 Fault Finding Chart Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 115: Special Tools

    073. Shaft 301. Piston Ring Compressor Figure 13-1: Piston Ring Compressor UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 13 - 1 Piston Ring Compressor Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 116: Figure 13-2: Locating Nut

    This is a special tool used to tighten or remove the locking nut (left-hand threaded) on the bearing assemblies.. 061. Labyrinth Locknut 305. C-spanner Figure 13-3: C-spanner UNCONTROLLED DOCUMENT Page 13 - 2 Locating Nut Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 117: Figure 13-4: Shaft Wrench

    Shaft damage occurs if other tools are used to hold the shaft. 073. Shaft 306. Shaft Wrench Figure 13-4: Shaft Wrench UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 13 - 3 Shaft Wrench Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 118: Tie-Down Instructions

    UNCONTROLLED DOCUMENT Page 14 - 1 Tie-down Instructions Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 119 5. Do not use any other points to restrain the transport cradle or the pump. 6. Ensure the straps are not choked over any grease or hydraulic lines. 7. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx).
  • Page 120 3. Keep the angle of the tie-down points within 45 degrees of the angle of the lug. 4. Only use chains where indicated. 5. Do not use any other points to restrain the transport cradle, baseplate, or the pump. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT...
  • Page 121 7. Ensure the straps are not choked over any grease or hydraulic lines. 8. Ensure the straps are not choked over motor terminal box (001) and motor fan housing (002). 9. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx).
  • Page 122 6. Ensure the straps are not choked over any grease or hydraulic lines. 7. Ensure the straps are not choked over motor terminal box (001) and motor fan housing (002). 8. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx).

  • Page 123: Lifting Instructions

    For information on how to carry out the lifting activity using the recommended equipment, refer to the instructions detailed in this section. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 2 Lifting Instructions Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 124 (001). 9. Store all lifting equipment in a dry, non corrosive environment. 10. All lifting points must be routinely inspected and maintained. 11. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-BSE-EN...
  • Page 125 1500 8. Store all lifting equipment in a dry, non corrosive environment. 9. All lifting points must be routinely inspected and maintained. 10. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-BSS-EN...

  • Page 126: Stuffing Box

    Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-SB-EN...
  • Page 127 Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-ER-EN Page 1 of 1 Document No.: DOC-04-000055...
  • Page 128 Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-SA-EN Page 1 of 1 Document No.: DOC-04-000058...
  • Page 129 Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-FPLI-EN...
  • Page 130 Working Load Limit (WLL) / Rated Capacity data. 5. All lifting equipment must be routinely inspected and maintained. 6. Store all lifting equipment in a dry, non-corrosive environment. 7. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-VL-EN Page 1 of 1 Document No.
  • Page 131 Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT...
  • Page 132 Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-TB-EN...

  • Page 133: Cover Plate

    Working Load Limit (WLL) / Rated Capacity data. 4. All lifting equipment must be routinely inspected and maintained. 5. Store all lifting equipment in a dry, non-corrosive environment. 6. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT...

  • Page 134: Suction Cover

    Working Load Limit (WLL) / Rated Capacity data. 3. All lifting equipment must be routinely inspected and maintained. 4. Store all lifting equipment in a dry, non-corrosive environment. 5. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-H-SC-EN...
  • Page 135 3. Store all lifting equipment in a dry, non corrosive environment. 4. All lifting points must be routinely inspected and maintained. 5. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-SN-EN Page 1 of 1 Document No.
  • Page 136 2. Store all lifting equipment in a dry, non corrosive environment. 3. All lifting points must be routinely inspected and maintained. 4. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). 1200...

  • Page 137: Baseplate Assembly

    6. Store all lifting equipment in a dry, non corrosive environment. 7. All lifting points must be routinely inspected and maintained. 8. If you need any assistance, please contact your local Weir Minerals Representative (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT Document Name: LFT-WARMAN-BPLT-EN...
  • Page 138 6. The centre of gravity for each pump will vary due to assembly configuration variations. 7. Store all lifting equipment in a dry, non corrosive environment. 8. All lifting points must be routinely inspected and maintained. 1200 9. If you need any assistance, please contact your local Weir Minerals Representative 1500 (www.weirminerals.com/contacts/worldwide.aspx). UNCONTROLLED DOCUMENT...
  • Page 139 16 Check pulley alignment. 17 Bump motor to check rotation. UNCONTROLLED DOCUMENT Page 14 - 3 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 140 Flow rate is the next most important requirement. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 4 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 141 CleanedInspect Oil flush Oil filled Cooling water piping Gearbox motor run Vibration test UNCONTROLLED DOCUMENT Page 14 - 5 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 142 11 Gearbox bearing stable temps 12 Gearbox vibration 13 Pump bearing stable temp UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 6 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 143 (Slowly open discharge valve from closed position, record on separate sheet if needed) UNCONTROLLED DOCUMENT Page 14 - 7 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 144 18 Turn off gland water after pump has come to a stop. 19 Remove commissioning tags. Other UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 8 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 145 0:10 0:15 0:30 0:45 1:00 1:15 1:30 1:45 2:00 2:15 2:30 2:45 3:00 UNCONTROLLED DOCUMENT Page 14 - 9 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 146 This may require installation of a load distribution ring between the connecting flange and the pump and may require high flange bolt torques. • Foundations must be adequately designed and constructed to accept the forces outlined on the Weir supplied general arrangement drawing.
  • Page 147 UNCONTROLLED DOCUMENT Page 14 - 11 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 148 Allowances for thermal growth need to be taken into consideration. Record cold alignment values on attached sheets. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 12 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 149 Assembly must be run for a minimum of 4 hours before shutting off. Monitor bearing temperatures. Record in attached sheet. UNCONTROLLED DOCUMENT Page 14 - 13 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...
  • Page 150 Record final hot alignment values in the attached sheet. UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 14 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...
  • Page 151 High Speed Gearbox, Motor Non Drive End Bearing h. Pump Non Drive End Bearing Assembly Bearing Temperatures Time Recorded UNCONTROLLED DOCUMENT Page 14 - 15 Checklists Document Name: IOM-WARMAN-AH-EN USER 3/Apr/2015 Rev 2.0 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. Document No: DOC-04-00048...

  • Page 152: Figure 14-1: Pump With Gear Box Housings

    Low Speed Gearbox, Pump Non Drive End Bearing Figure 14-1: Pump with Gear Box Housings UNCONTROLLED DOCUMENT Document Name: IOM-WARMAN-AH-EN USER Page 14 - 16 Checklists Document No: DOC-04-00048 Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved. 3/Apr/2015 Rev 2.0...

  • Page 153: Genuine Parts

    Spare parts for Warman pumps consist in the main of liners, impellers, bearings, shaft sleeves, seals, and shaft seal parts. Weir Minerals recommends that sufficient spares are kept in stock based on expected wear life of each part to maximise operational availability of installed pumps.
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