Electric Motor Powered Pump Unit Minerals MEFP-420HV Electric Pump Pontoon Assembly, Installation, Operation, Maintenance, and Parts Manual Installation, Operation, Maintenance, and Parts Manual Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. MULTIFLO®, VACTRONIC®, and HYDRAU-FLO® are registered trademarks of Weir Minerals Australia Ltd. This document contains information confidential to Weir Minerals Australia Ltd. It should not be disclosed in whole or in part to parties other than the recipient without the express written permission of Weir Minerals Australia Ltd. authorized personnel. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Issue Date: 13 October 2017 Electric Motor Powered Pump Unit Minerals MEFP-420HV Electric Pump Pontoon Assembly, Installation, Operation, Maintenance, and Parts Manual Project Information Manufacturer Name: Multiflo® Customer Name: Weir Minerals Colombia Location: Colombia, South America Project Name: Multiflo® Model ME-420HV Electric Pump Pontoon Equipment Identification Number: MEFP-420HV-195-08.28 Multiflo® Job Number: MFAU3159-01 Equipment Description: Multiflo® Model ME-420HV Electric Pump Pontoon, Flood Primed Pump Unit. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page i Issue Date: 13 October 2017 Electric Motor Powered Pump Unit Minerals MEFP-420HV Electric Pump Pontoon Assembly, Installation, Operation, Maintenance, and Parts Manual Revision History Revision Description Reviewed Authorised Date Version 1.0 IOM manual Bob Turner Weir Minerals Australia 13/10/2017 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page ii Issue Date: 13 October 2017 Electric Motor Powered Pump Unit Minerals MEFP-420HV Electric Pump Pontoon Assembly, Installation, Operation, Maintenance, and Parts Manual Contact Details Australia Queensland (QLD): Head Office ® Multiflo 15 Dacmar Road Coolum Beach Qld 4573 Ph: 07 5449 3032 Fax: 07 5446 4304 Email: [email protected] Rockhampton Authorised Service Provider Weir Minerals Service Centre 80 McLaughlin Street North Rockhampton QLD 4701 Ph: 07 4924 7700 Fax: 07 4924 7799 Email: [email protected] Western Australia (WA): Kimberly, Pilbara, MidWest, Murchison Region Weir Minerals Australia Ltd. WA Head Office 41 Kewdale Road Kewdale, WA, 6105 Ph: 08 9366 2700 Fax: 08 9366 2766 Local contact details: South West Region Authorised Service Provider Weir Minerals Australia Ltd. Bunbury Service Centre 1 Shanahan Road Bunbury WA 6230 Ph: 08 9726 2301 Fax: 08 9726 2303 Kalgoorlie & Goldfields Authorised Service Provider Weir Minerals Australia Ltd. Kalgoorlie Service Centre 30 Atbara Street Kalgoorlie WA 6430 Ph: 08 9021 1454 Fax: 08 9021 1468 Perth Metro Authorised Service Provider Weir Minerals Australia Ltd. Henderson Service Centre 20 Stuart Drive Henderson WA 6166 Ph: 08 9419 7500 Fax: 08 9410 7510 New South Wales (NSW): Hunter Valley Authorised Service Provider Weir Minerals Australia Ltd. Beresfield Service Centre 9 Arunga Drive Beresfield NSW 2322 Ph: 02 4032 9412 Fax: 02 4032 9497 Indonesia PT Weir Minerals Indonesia Jl. Mulawarman No. 020 RT. 020 Kelurahan Manggar, Balikpapan 76116, East Kalimantan Indonesia Ph: 62 542 746098 Fax: 62 542 746099 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 Tanjung branch Office: Jl.Ahmad Yani Km 7.5 RT.01 Maburai. Kecamatan Murung Pudak, Tanjung - Tabalong, South Kalimantan. Phone: +62 526 - 2712267 Sangatta branch Office: Jl.Yos Sudarso IV RT.23 No.25 Desa Teluk Lingga, Kecamatan Sangatta Utara. Kabupaten Kutai Timur, Sangatta - East Kalimantan. Phone: +62 549 25584 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page iii Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Table of Contents Project Information ................................................................................................................................. i Revision History .................................................................................................................................... ii Contact Details ...................................................................................................................................... iii Table of Contents ................................................................................................................................. iv List of Figures ....................................................................................................................................... ix List of Tables .......................................................................................................................................... x 1 Introduction ............................................................................................................................... 1-1 1.1 Scope of the Manual ..................................................................................................... 1-1 1.2 Intended Audience ........................................................................................................ 1-1 1.3 Disclaimer ..................................................................................................................... 1-1 1.4 Copyright....................................................................................................................... 1-1 2 Safety ......................................................................................................................................... 2-3 2.1 Safety Symbols ............................................................................................................. 2-4 2.2 Safety Symbols used on the Pump Unit ....................................................................... 2-6 2.3 General Safety .............................................................................................................. 2-7 2.4 Qualified Workers ......................................................................................................... 2-7 2.5 Safety Working on Pumps ............................................................................................ 2-7 2.6 Safety Equipment ......................................................................................................... 2-8 2.7 Risks ............................................................................................................................. 2-8 2.8 Operating Conditions .................................................................................................... 2-8 2.9 Material Safety Data Sheets ......................................................................................... 2-8 2.10 Intended Use of the Product ......................................................................................... 2-8 2.11 Unintended Use of the Product .................................................................................... 2-9 2.12 Warranty ....................................................................................................................... 2-9 3 Technical Data ........................................................................................................................ 3-11 3.1 Pump Unit Data .......................................................................................................... 3-11 3.2 Manufacturer and Product Information ....................................................................... 3-14 4 Pump Unit Description ........................................................................................................... 4-15 4.1 Environmental Conditions ........................................................................................... 4-15 4.2 Major Components ..................................................................................................... 4-15 4.2.1 Electric Motor ...................................................................................................... 4-16 4.2.2 Bare Shaft Pump ................................................................................................ 4-16 4.2.3 Drive Belts ........................................................................................................... 4-18 4.3 5 Centre of Gravity and Mass ........................................................................................ 4-19 Transport and Storage ........................................................................................................... 5-20 5.1 Transport..................................................................................................................... 5-20 5.2 Transportation Safety ................................................................................................. 5-20 5.3 Chain of Responsibility ............................................................................................... 5-20 5.4 Load Restraint ............................................................................................................ 5-21 5.5 Load Restraining Tools ............................................................................................... 5-22 5.6 Pump Unit Packing and Delivery ................................................................................ 5-22 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page iv Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5.7 Packing ....................................................................................................................... 5-22 5.8 Receiving .................................................................................................................... 5-23 5.9 Loading and Unloading ............................................................................................... 5-23 5.10 Reporting Shipping Shortage ..................................................................................... 5-23 5.11 Storage Recommendations after the Pump Unit is Assembled ................................. 5-23 5.12 Repacking ................................................................................................................... 5-23 5.13 Fire Suppression and Fire Extinguishers .................................................................... 5-23 5.14 Pump Unit Lifting and Moving ..................................................................................... 5-24 5.14.1 Preparation for Lifting ......................................................................................... 5-24 5.14.2 Lifting Instructions for Pump Unit ........................................................................ 5-24 5.14.3 Moving Instructions for Pump Unit ...................................................................... 5-26 5.15 Storage ....................................................................................................................... 5-26 5.15.1 Short Term Storage (<12 Months) ...................................................................... 5-26 5.15.2 Long Term Storage (>12 Months) ...................................................................... 5-27 5.15.3 Inspection during Storage ................................................................................... 5-27 6 Assembly and Installation ..................................................................................................... 6-28 6.1 Safety Notes during Assembly ................................................................................... 6-28 6.2 Safety Notes during Installation and Moving .............................................................. 6-29 6.3 Space Requirements .................................................................................................. 6-29 6.4 Pre-installation ............................................................................................................ 6-29 6.4.1 Pre-installation Checks ....................................................................................... 6-29 6.4.2 Pump Site Preparation ........................................................................................ 6-30 6.4.3 Moving and Locating the Pump Unit ................................................................... 6-30 6.4.4 Pipework Attachment .......................................................................................... 6-30 6.4.5 Confined Spaces ................................................................................................ 6-30 6.4.6 Hazards ............................................................................................................... 6-31 6.4.7 Identification of Confined Spaces ....................................................................... 6-31 6.4.8 General Placement of the Pump......................................................................... 6-32 6.4.9 Placement in an Area with Potentially Flammable or Explosive Atmosphere .... 6-32 6.4.10 Safety Notes during Assembly............................................................................ 6-33 6.4.11 Safety Notes during Installation and Moving ...................................................... 6-34 6.4.12 Space Requirements .......................................................................................... 6-34 6.5 Assembly .................................................................................................................... 6-35 6.5.1 Discharge Components Assembly...................................................................... 6-35 6.5.2 Pre-assembly Checklist ...................................................................................... 6-35 6.6 Assembly of Pontoon .................................................................................................. 6-36 6.6.1 6.7 Preparation for Lifting ......................................................................................... 6-49 Positioning .................................................................................................................. 6-50 6.7.1 Removing ............................................................................................................ 6-50 6.7.2 Installation Checks .............................................................................................. 6-51 6.7.3 Pipe Guidelines ................................................................................................... 6-52 6.7.4 Pressure Pipe ..................................................................................................... 6-53 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page v Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6.7.5 7 Suction Strainer .................................................................................................. 6-53 Operation ................................................................................................................................. 7-54 7.1 Operation Safety ......................................................................................................... 7-54 7.1.1 Electric Motor Safety Notes ................................................................................ 7-55 7.1.2 Bare Shaft Pump Safety Notes ........................................................................... 7-55 7.1.3 Taperlock Bushes ............................................................................................... 7-55 7.1.4 Noise and Radiation ........................................................................................... 7-55 7.2 General Description and Function of the Equipment .................................................. 7-56 7.2.1 Principle of Operation ......................................................................................... 7-56 7.2.2 Pump Unit Orientation ........................................................................................ 7-56 7.2.3 Daily Pre-start Checks ........................................................................................ 7-56 7.2.4 Starting Procedure .............................................................................................. 7-57 7.2.5 Bumping the Motor ............................................................................................. 7-58 7.3 Abnormal Condition .................................................................................................... 7-59 7.3.1 Cavitation ............................................................................................................ 7-59 7.3.2 Recirculation ....................................................................................................... 7-59 7.3.3 Vibration .............................................................................................................. 7-60 7.3.4 Severe Weather Events ...................................................................................... 7-60 7.3.5 Lack of Maintenance Procedures ....................................................................... 7-60 7.3.6 Fire ...................................................................................................................... 7-60 7.3.7 Oil Leak or Spill ................................................................................................... 7-60 7.4 Normal Operation ....................................................................................................... 7-61 7.5 Monitoring during Operation ....................................................................................... 7-61 7.5.1 Electric Motor Operation Procedures, Startup Procedures and Shutdown Procedures.......................................................................................................................... 7-61 7.6 Draining the Pump when there is a Danger of Freezing ............................................ 7-62 7.7 Monitoring of Pump Parameters ................................................................................. 7-62 8 Maintenance ............................................................................................................................ 8-63 8.1 General Maintenance ................................................................................................. 8-63 8.2 Safety Instructions during Maintenance, Repair and Inspection ................................ 8-63 8.3 Isolation of Discharge Pipework ................................................................................. 8-64 8.4 Normal Maintenance Procedures ............................................................................... 8-65 8.4.1 Maintenance Safety Notes .................................................................................. 8-65 8.4.2 Bare Shaft Pump Safety Notes ........................................................................... 8-66 8.5 Isolation Procedure ..................................................................................................... 8-67 8.5.1 Electric Motor ...................................................................................................... 8-67 8.5.2 Maintenance – Bare Shaft Pump ........................................................................ 8-67 8.5.2.1 Gland Packing............................................................................................. 8-68 8.5.2.2 Impeller ....................................................................................................... 8-70 8.5.3 Check Valve/Non-return Valve ........................................................................... 8-71 8.5.4 Drive Belts ........................................................................................................... 8-71 8.5.5 Strainer ............................................................................................................... 8-71 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page vi Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.6 Maintenance and Service Guide ................................................................................ 8-72 8.6.1 Every 10 Operating Hours or Daily ..................................................................... 8-72 8.6.2 Every 250 Operating Hours (Perform in addition to Daily Schedule Items) ....... 8-72 8.6.3 Every 500 Operating Hours (Perform in addition to 250 hrs Schedule Items) ... 8-73 8.6.4 Every 1000 Operating Hours (Perform in addition to 500 Hours Service Items) 8-73 8.6.5 73 Every 2000 Operating Hours (Perform in addition to 1000 Hours Service Items) .. 8- 9 Lubrication .............................................................................................................................. 9-74 9.1 Safety .......................................................................................................................... 9-74 9.2 Pump Unit Lubrication Schedule ................................................................................ 9-75 9.2.1.1 10 Bare Shaft Pump - Greasing Unit ............................................................... 9-76 Troubleshooting ................................................................................................................... 10-77 10.1 Safety ........................................................................................................................ 10-77 10.2 Bare Shaft Pump ...................................................................................................... 10-78 10.3 V-belts ....................................................................................................................... 10-78 10.4 Re-starting the Pump Unit after an Intervention ....................................................... 10-79 11 Dismantling and Disposal ................................................................................................... 11-80 11.1 Safety Notes – Dismantling and Disposal ................................................................ 11-80 11.2 Decommissioning and Dismantling .......................................................................... 11-81 11.2.1 Pump Base Dismantling ................................................................................... 11-81 11.2.2 Dismantling the Pontoon (with the centreframe removed from the pontoon) ... 11-82 11.3 Disposal .................................................................................................................... 11-82 11.3.1 12 General Disposal .............................................................................................. 11-82 Appendix ............................................................................................................................... 12-83 12.1 Certifications ............................................................................................................. 12-83 12.1.1 OHSAS 18001:2007 ......................................................................................... 12-83 12.1.2 AS/NZS 4801:2001 ........................................................................................... 12-84 12.1.3 AS/NZS ISO 14001:2004 .................................................................................. 12-85 12.1.4 AS/NZS ISO 9001:2008 .................................................................................... 12-86 12.2 General Sales Condition ........................................................................................... 12-87 12.3 Spare Parts List ........................................................................................................ 12-91 12.3.1.1 Major Components - Pontoon Assembly .................................................. 12-92 12.3.1.2 Major Components - Pontoon Assembly (continued) ............................... 12-93 12.3.2 12.4 Major Components - Cassette Assembly ......................................................... 12-94 Pump Cassette ......................................................................................................... 12-95 12.4.1 Drive Belts and Guards ..................................................................................... 12-96 12.4.2 Discharge Assembly ......................................................................................... 12-97 12.4.2.1 12.5 Discharge Assembly (continued) .............................................................. 12-98 Handrails – Pontoon LH Float Assembly .................................................................. 12-99 12.5.1 Handrails – Pontoon RH Float Assembly ....................................................... 12-100 12.5.2 Centreframe – Pontoon .................................................................................. 12-101 12.5.3 Centreframe – Pontoon (continued) ............................................................... 12-102 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page vii Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6 Bare Shaft Pump .................................................................................................... 12-103 12.6.1 Bare Shaft Pump (continued) ......................................................................... 12-104 12.6.2 Bearing Assembly – Wet End ......................................................................... 12-105 12.6.2.1 Bearing Assembly – Drive End ............................................................... 12-106 12.6.3 Gland and Packing Kit .................................................................................... 12-107 12.6.4 Wet End Parts ................................................................................................. 12-108 12.6.5 Wet End Parts (continued) .............................................................................. 12-109 12.6.6 Bearing Housing Assembly............................................................................. 12-110 12.6.7 Ladder Tray Assembly .................................................................................... 12-111 12.6.8 Life Ring .......................................................................................................... 12-112 12.6.9 Electro – Luber Mount .................................................................................... 12-113 12.7 Checklists................................................................................................................ 12-114 12.7.1 12.8 Field Observation Checklist ............................................................................ 12-114 Tightening Torque Values....................................................................................... 12-115 12.8.1 Metric Hex Bolts & Screw ............................................................................... 12-115 12.9 List of Accompanying Manuals ............................................................................... 12-116 12.10 Reference Documents ........................................................................................ 12-116 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page viii Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT List of Figures Figure 3-1: Pump curve .............................................................................................................. 3-13 Figure 4-1: Major components of MEP-420HV pump pontoon .................................................. 4-15 Figure 4-2: Bare shaft pump ....................................................................................................... 4-16 Figure 4-3: Bare shaft pump wet end parts ................................................................................ 4-17 Figure 4-4: Bearing assembly ..................................................................................................... 4-17 Figure 4-5: Pontoon assembly centre of gravity ......................................................................... 4-19 Figure 5-1: Load restraint ........................................................................................................... 5-21 Figure 5-2: Over-centre load chain binder .................................................................................. 5-22 Figure 5-3: Pontoon assembly lifting points................................................................................ 5-25 Figure 5-4: Pontoon tow points ................................................................................................... 5-25 Figure 6-1: Confined space warning signs ................................................................................. 6-31 Figure 6-2: Fitting strainer to BSP .............................................................................................. 6-36 Figure 6-3: Fitting handrails and kickplates to centreframe........................................................ 6-36 Figure 6-4: Fitting handrails and kickplates to RH hull ............................................................... 6-37 Figure 6-5: Fitting handrails and kickplates to LH hull ................................................................ 6-37 Figure 6-6: Assembly of LH float ................................................................................................ 6-38 Figure 6-7: Assembly of LH float ................................................................................................ 6-39 Figure 6-8: Assembly of LH float ................................................................................................ 6-40 Figure 6-9: Assembly of RH float ................................................................................................ 6-41 Figure 6-10: Assembling pontoon stairs ..................................................................................... 6-41 Figure 6-11: Discharge assembly ............................................................................................... 6-42 Figure 6-12: Assembling Discharge assembly ........................................................................... 6-43 Figure 6-13: Assembly of ladder tray .......................................................................................... 6-44 Figure 6-14: Assembly of motor ................................................................................................. 6-45 Figure 6-15: Fitting belt guard back plate ................................................................................... 6-46 Figure 6-16: Assembly of motor pulley ....................................................................................... 6-46 Figure 6-17: Fitting belts ............................................................................................................. 6-47 Figure 6-18: Fitting belt guard-cover assembly .......................................................................... 6-47 Figure 6-19: Fitting life ring assembly ......................................................................................... 6-48 Figure 6-20: Fitting connection box ............................................................................................ 6-48 Figure 6-21: Lifting the unit with chains ...................................................................................... 6-49 Figure 7-1: Pump unit orientation ............................................................................................... 7-56 Figure 7-2: Result of cavitation ................................................................................................... 7-59 Figure 7-3: Result of recirculation on Front Door/Throat Bush................................................... 7-59 Figure 8-1: Gland packing removal tool...................................................................................... 8-68 Figure 8-2: Impeller clearance .................................................................................................... 8-70 Figure 9-1: Greasing guide for Warman 10/6 FFG bearing assembly if greasing manually ...... 9-75 Figure 9-2: Auto-greaser - Electro-Luber.................................................................................... 9-76 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page ix Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT List of Tables Table 1-1: Manual Organisation ................................................................................................... 1-2 Table 2-1: Safety Colours ............................................................................................................. 2-4 Table 2-2: Safety Symbols............................................................................................................ 2-5 Table 2-3: Pump Unit Safety Symbols .......................................................................................... 2-6 Table 3-1: Pump Data................................................................................................................. 3-11 Table 3-2: Pump Data – Pump Cassette .................................................................................... 3-12 Table 7-1: Daily Pre-start Checklist ............................................................................................ 7-56 Table 8-1: Maintenance and Service Guide for every 10 Operating Hours ............................... 8-72 Table 8-2: Maintenance and Service Guide for every 250 Operating Hours ............................. 8-72 Table 8-3: Maintenance and Service Guide for every 500 Operating Hours ............................. 8-73 Table 8-4: Maintenance and Service Guide for every 1000 Operating Hours ........................... 8-73 Table 8-5: Maintenance and Service Guide for every 2000 Operating Hours ........................... 8-73 Table 9-1: Grades and Frequency of Lubrication ....................................................................... 9-75 Table 10-1: Troubleshooting Guide .......................................................................................... 10-78 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page x Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 1 Introduction Introduction The purpose of this manual is to aid and instruct installers, operators, and repairers of the Multiflo® pump unit in the recommended safety, installation, operation, and maintenance of associated equipment. The Multiflo® pump unit is of robust construction and is designed to be used as a mine dewatering pump in accordance with the pump performance data contained in this manual. Following all recommended instructions is paramount to ensure long life, trouble-free operation, and consistent high performance. All content incorporated in this manual must be strictly followed, read, and understood by all persons responsible for the safety, operation, installation, and maintenance of the pump unit. It is recommended that the full extent of this manual be understood prior to commissioning in order to understand instructions for undertaking regular periodic maintenance of the pump unit. When correctly installed and appropriate training is undertaken as per the IOM instructions, the pump unit will achieve high levels of reliability. To meet the consistent high performance that the pump unit is designed to achieve, it is important that the instructions contained in the pump unit manual are understood and carried out by all users of this product. 1.1 Scope of the Manual The manual must be used only as a reference in conjunction with Weir Minerals Australia product-specific training. For further information, contact Weir Minerals Australia. 1.2 Intended Audience This manual is intended for: Weir Minerals Australia service personnel. The personnel who have a relevant basic level of trade/professional competency. CAUTION PERSONNEL INJURY The pump or pump unit must be installed, operated, and maintained only by personnel who are trained and have sufficient knowledge about the hazards that may occur during operation. 1.3 Disclaimer Despite of the care taken to compile all information and illustration in this document, neither the author nor the publisher can be held liable for any consequential damages resulting from possible errors in this publication. The English language is used to write the original manual. Any versions in other languages are translations of the original manual instructions. These translated versions may contain information that differs from the original due to interpretation of the content and meaning of the original text. In case of such discrepancies, the original English language instructions will be considered the sole authentic source for the purpose of determining the content and meaning of the text. Weir Minerals Australia reserves the right to make changes to technical and design specifications at any time without prior notice. 1.4 Copyright Weir Minerals Australia Pty. Ltd. 2017. This document is subject to copyright. Use or copying of this document in whole or part without the written permission of Weir Minerals Australia constitutes an infringement of copyright. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 1 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Introduction Table 1-1 describes the organisation of the manual. Table 1-1: Manual Organisation Chapter Description ® Introduction Contains an introduction to the Multiflo pump unit and the scope of the manual. Safety Lists the safety guidelines that must be adhered to while installing, operating and maintaining the pump. Technical Data Contains the technical aspects of the pump unit. Description Describes the working principle and different components of the pump/pump unit. Transport and Storage Provides information on safety guidelines and procedures to follow while delivering the pump/pump unit to a customer location, bringing the pump to workshop for maintenance, and storing the pump unit. Assembly and Installation Lists the procedures to assemble and install the pump unit. Operation Contains the information on pump pre-start up procedures, pump startup, problems that may occur during the pump startup, and shutdown procedures. Maintenance Lists running and overhaul maintenance procedures. Troubleshooting Provides information regarding various problems that may occur during pump operation and respective solutions. Decommissioning and Disposal Provides guidelines regarding taking a pump/pump unit out of service, and disposing or selling. Appendix Contains spare parts list for the pump unit and additional information like checklists and list of accompanying manuals and reference documents. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 2 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 2 Safety Safety The instructions within this chapter must be followed and carried out accordingly to ensure a safe and efficient operation. The Multiflo® pump unit is designed to be used as a mine dewatering pump in accordance with the pump performance data contained in this manual. It is the user’s responsibility to be aware of and comply with all federal and state occupational health and safety requirements. The Multiflo® pump unit has been designed to provide a safe working environment for the operators, maintenance personnel and others. Improper operation, installation, maintenance, or repair of this equipment could result in injury or death. Good, Robust Health, Safety and Environmental Systems, Processes and Practices are undoubtedly an important aspect of operating safely. Do not operate or perform any operation, installation, maintenance, or repair on this product, until you have read and understood the operation, installation, and maintenance and repair information contained in the supplied documentation. Personal protective equipment (PPE) must be used when installing, operating, servicing, maintaining, and repairing this equipment. It is the user’s responsibility to be aware of and comply with all federal and state occupational health and safety requirements. Use trained competent people to assess all site OHSE risks involved with the installation of this equipment in accordance with the installation, and operations manual (IOM) supplied by Multiflo®. Use the correct, safe, and appropriate equipment related to the site conditions. SAFETY WARNINGS AND PRECAUTIONS ARE PROVIDED IN THIS SECTION. FAILURE TO HEED THESE WARNINGS AND PRECAUTIONS MAY RESULT IN PERSONAL INJURY AND/OR DEATH TO YOURSELF AND/OR OTHERS ALONG WITH THE RESULTS OF EQUIPMENT AND ENVIRONMENTAL DAMAGES. Living by our five key safety values and commitment to following safety procedures will enable us all to make the work place a safer environment. Our Five Key Safety Values are: My colleagues and my own safety are paramount; No task is so important or urgent that it cannot be undertaken safely; I will not only undertake tasks that I am trained, competent and properly prepared for; I will never cut corners, nor take shortcuts at the expense of safety; and I will stop the job if I believe it is unsafe to continue. Any aspect of the installation, which the customer is unsure of, we advise the customer to discuss with Weir Minerals Australia representative. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 3 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 2.1 Safety Safety Symbols The safety colours incorporated in this manual are indicated in Table 2-1. These colours serve as a guide to the associated risk with the given safety symbols. Table 2-1: Safety Colours Signal Warning Level Description DANGER Danger Indicates a hazard with high level of risk which, if not avoided, could result in death or catastrophic equipment damage. Warning Indicates a hazard with a medium level of risk which, if not avoided, could result in serious or moderate injury, or serious equipment damage. CAUTION Caution Indicates a hazard with a low level of risk which, if not avoided, could result in moderate or minor injury, or moderate equipment damage. NOTICE Notice Indicates important information for the user. WARNING Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 4 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Safety The documentation supplied with the Multiflo® pump unit utilises the following safety symbols listed in Table 2-2 to highlight potential harmful situations to personnel, equipment, and the environment as per ISO 9001:2008. Table 2-2: Safety Symbols Symbols Definitions Consequences Imminent risk of fatal or crippling injuries Fatal or crippling injuries likely to result from any exposure Possibility of a harmful situation Minor or slight injuries possible Mandatory instructions Failure to follow may lead to fatality, injuries or damage to property and environment Prohibited activities Possible damage to the product, equipment, or property Warning of electrical shock Fatal or crippling injuries likely to result from any exposure Mandatory personal protective equipment (PPE) Fatal or crippling injuries likely to result if the correct PPE is not worn Explosion warning Possibility of explosion if instructions not followed Application hints and other useful information Refer to the accompanying manual specified Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 User has to refer specified accompanying manuals or external documents UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 5 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 2.2 Safety Safety Symbols used on the Pump Unit The Multiflo® pump unit utilises the following safety symbols to highlight potentially harmful situations to personnel, equipment, and the environment as per ISO/CE/ANSI format. It is the user’s responsibility to be aware of and comply with all federal and state occupational health and safety requirements. Table 2-3: Pump Unit Safety Symbols Symbols Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 Definitions Consequences Hot surface. Do not touch. Fatal or crippling injuries likely to result from any contact. Push for emergency stop. Pump unit operation stops if pressed. Lifting point Designated lifting points only to be used for lifting operations. Possibility of a harmful situation. Indicates adjoining parts are hot. Mandatory personal protective equipment to be worn. Fatal or crippling injuries likely to result from any contact. Fatal or crippling injuries likely to result if not worn. Read and understand technical manual before servicing or performing any operations. Fatal or crippling injuries likely to result if proper procedures are not followed. Not a lifting point. Tie down point. Do not lift or tow from this point. Fatal or crippling injuries likely to result if not followed. Possible damage to the Product if used for lifting. Mandatory personal protective equipment to be worn for protection against noise. Damage to hearing likely to result if not worn. Refer to the operation manual. User has to refer to the operation manual. UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 6 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 2.3 Safety General Safety Use of the pump for an application and/or deployment of the pump in an environment other than defined at the time of purchase is strictly prohibited and can result in a hazardous situation. This is particularly true for corrosive, poisonous, or other hazardous liquids. The pump or pump unit may only be installed, operated, and maintained by persons who are competent and are aware of the dangers of working with it. These instructions are intended to facilitate familiarisation with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. These instructions may not take into account local regulations. It is the responsibility of the purchaser of the product to ensure such regulations are observed by all, including those installing the product. Always coordinate repair activities with operations personnel and follow all plant safety requirements, applicable workplace health and safety laws and regulations. The equipment must not be put into service until all the conditions relating to workplace health and safety in the instructions are met. Information in these user instructions is believed to be reliable. Despite of all the efforts to provide correct and necessary information the content of this manual may appear insufficient and is not guaranteed as to its completeness or accuracy. It is not permitted to make changes to the pump or pump unit without written permission from Weir Minerals Australia. If any changes are made to the product without the written permission of the Weir Minerals Australia, then Weir Minerals Australia disclaims all liability. Hearing protection must be worn if the sound emission level exceeds 85 dB (A). 2.4 Qualified Workers All personnel involved in the operation, installation, inspection and maintenance of the pump must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided by a suitable qualified trainer. If required, the operator may engage the manufacturer/supplier to provide applicable training. Always coordinate repair activities with operations and workplace health and safety personnel and follow plant safety requirements and applicable workplace health and safety laws and regulations. 2.5 Safety Working on Pumps The Multiflo® centrifugal pump is a piece of rotating equipment which contains pressure under service conditions. All standard safety precautions for such equipment must be followed before and during installation, operation, and maintenance. Drain the pump and isolate pipework before dismantling the pump. The appropriate workplace health and safety precautions must be taken where the pumped liquids are hazardous. Mixing of new and worn pump components may increase the incidence of premature pump wear and leakage. All metal mating faces must be cleaned of dirt, rust, paint, and other adhering substances prior to pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to catastrophic failure of parts. Avoid contamination: Burning of elastomer pump components causes emission of toxic fumes and results in air pollution which leads to personnel injury/illness. Leakage in excess of the specified packing lubrication requirements from pump shaft seals and/or leakage from worn pump components or seals, causes water and/or soil contamination. Liquid waste disposal from servicing of pumps or stagnant water from pumps stored for long periods, causes water and/or soil contamination. The pontoon is integrated with guardrails to provide/ensure safety when walking/working around the pontoon. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 7 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 2.6 Safety Safety Equipment The correct safety equipment (PPE) and safety instruction for pump or pump unit operation must be carried out accordingly in assigned areas. It is the user’s responsibility to carry out assigned safety rules. If any incidents/accidents occur due to unsafe act the user is held liable for all cause and responsibility. 2.7 Risks It is the user’s responsibility to perform the risk analysis specific to the application of the pump unit and the site conditions. It is the user’s responsibility to understand all the inherent risks and consequences involved during Moving, Locating, Positioning, Assembly, Installation, Operation, and Maintenance procedures and take necessary precautions against such risks. Adequate safety measures MUST be taken before performing any operation. 2.8 Operating Conditions The standard ambient operation temperatures recommended are 0 °C to +45 °C. If the operating range is outside this contact your local Weir Minerals representative for more information. CAUTION FAILURE DUE TO OPERATING CONDITIONS If the pump is operated outside the recommended temperature ranges, it may cause mechanical failure leading to safety issues. 2.9 Material Safety Data Sheets Material safety datasheets document the information on the properties of hazardous materials and how they may affect Workplace Health and Safety. Material safety data sheets include information on the identification of the chemical, health hazards, safe storage, and handling procedures, emergency information and disposal procedures. Multiflo® pump sets are produced with a range of materials and operate with a range of chemicals, including but not limited to; steel, plastics, paint, coolant, oil, fuel and grease. For specific material safety datasheets, please contact Weir Minerals Australia. 2.10 Intended Use of the Product The pump unit is designed to be used only as mine dewatering equipment in accordance with the pump performance data contained in this manual. The pump unit’s application is to move liquids (non-corrosive and non-explosive). The specific gravity of the liquid should be less than or equal to 1.05. The maximum liquid temperature is 70 oC (150 F). The operational pH range for the pump unit is 5 – 9. For further information on the operational range of the pump model, please contact your nearest Weir Minerals Australia representative for more information. It is the user’s responsibility to ensure that pump unit as a whole or any of its components are not used for any other purpose other than the intended usage mentioned in this manual. The procedures followed must be in line with the technical data and instructions provided in this manual. The pump unit should not be used in an environment with an explosive atmosphere as described in the ATEX directives. It is forbidden to physically modify any components of the pump unit or the pump unit as a whole. Weir Minerals Australia does not take responsibility if the pump unit was used after such modifications. If the conditions of service on the purchase order are going to be changed (for example liquid pumped, temperature or duty), it is requested that the user seek the manufacturer’s written agreement before startup. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 8 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Safety 2.11 Unintended Use of the Product The pump unit is not designed to pump flammable and/or explosive substances. Therefore, it is not permitted to have working fluids that are outside the allowable types stated by the manufacturer. The standard pump or pump unit must also not work in an environment in which there is a danger of fire and/or explosion. The pump unit should not be used in an environment with an explosive atmosphere as described in the ATEX directives. The pump or pump unit must only be used for applications that are listed in the intended use section of this manual. It is not permitted to use the pump for any application and/or field of activity other than that for which the pump was originally specified and installed without written permission from Weir Minerals Australia. CAUTION Weir Minerals Australia is not responsible for incorrect use and/or application of the pump. Pump units are designed to operating in a certain environment. If the pump unit is used outside of this operating range, premature failure could occur. Pumping of corrosive or abrasive mediums without appropriate countermeasures will lead to premature failure. If the pumps have not been designed to meet a duty outside of the customer specification, the customer will be liable for any damages due to misuse of the pump. 2.12 Warranty If within a period of 12 months from the date of delivery (“warranty period”) the Equipment is found to be defective in materials or workmanship, or do not conform to any applicable drawings and specifications approved in writing by Weir Minerals Australia, or (in the case of Equipment which is Weir-manufactured pumps) do not perform in accordance with the current applicable water performance curves supplied as part of the Weir quotation or published by Weir as at the date of the quotation (within the tolerances specified in applicable Australian Standards), then Weir will, at its option, either repair or provide replacement parts or Equipment provided that: a) Purchaser has given written notice to Weir of any alleged defect within the warranty period; b) Purchaser has provided Weir a reasonable opportunity to perform all appropriate tests on the Equipment; c) The defective Equipment or parts are promptly returned to a designated Weir service centre. Any defective Equipment or parts replaced will become Weir property and the repaired or new Equipment or parts will be delivered free to Purchaser’s site; and d) No warranties are given by Weir as to the water performance of pumps other than in a test facility designated by Weir. For repaired Goods, excluding rubber lining, the warranty period is 6 months from the date of repair and shall only apply to Goods or parts repaired or replaced by Weir. No separate warranty shall apply to repair Goods as a whole or to parts not repaired or replaced by Weir. This warranty does not apply to repair of rubber. For rubber lining services the warranty period is 12 months from the date of application if the application is performed in accordance with Weir Minerals Standards RL101 Linatex Adhesives & Bonding and RL120 Lining Equipment & Vessels. Copies of these standards will be provided on request. The warranties given by Weir above do not cover: a) Fair “wear and tear”, or failures or damage not reported to Weir within the warranty period; b) Failures or damage due to misapplication, abuse, improper installation or abnormal conditions of operation; c) Failures or damage due to operation, either intentional or otherwise, above or below rated capacities or in an otherwise improper manner; Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 9 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Safety d) Failures or damage resulting from Goods which have been in any way tampered with or altered by anyone other than an authorised representative of Weir; e) Goods damaged in shipment or without the fault of Weir; f) Failures or damage resulting from the incorporation of, or failure of, non-Weir manufactured or supplied parts in the Goods; or g) Repairs to rubber lining. Weir does not warrant any equipment or other goods of other manufacturers which is designated by Purchaser or purchased by Weir for resale to Purchaser either separately or as a part of or operating in conjunction with equipment or other goods manufactured by Weir. For such equipment or other goods, Purchaser must rely on the warranty given by the manufacturer of the equipment or other goods. When Weir supplies Services to Purchaser including laboratory testing, process development, equipment selection, design (as part of design and manufacture), detail, contract supervision and contract management, Weir shall exercise due care and skill in undertaking such Services. Weir’s total liability under any contract shall in no event exceed the total price of the Goods and/or Services supplied. If any term, condition, guarantee or warranty is implied by law, including the Australian Consumer Law, which cannot be excluded or modified, then the term, condition, guarantee or warranty shall be deemed to be included and the exceptions and limitations do not apply to such term, condition, warranty or guarantee, provided that Weir’s liability for a breach of or failure to comply with any such term, condition, warranty, or guarantee (other than a guarantee under sections 51, 52 or 53 of the Australian Consumer Law) including any consequential loss which the Purchaser may sustain, shall be limited, at the option of Weir, to either replacing or repairing the Goods or, in the case of Services, to supplying the Services again. All conditions, warranties, terms, undertakings, representations, guarantees and obligations, not expressly set out in any written contract, whether arising under statute, common law, equity, custom, trade usage or otherwise (including without limitation, any implied condition, warranty, term, representation or guarantee as to the correspondence of the Goods or Services with any contract description or as to merchantable quality, fitness for any purpose or safety of the Goods or Services, or operating performance where such performance is conditional on empirical factors or on the whole installation or on the individual or overall operation or on the skills of an operator), whether made known or not and any liability of Weir to compensate or indemnify any person or persons in respect of the foregoing, are expressly negatived and excluded; In no event shall Weir be liable for any special, indirect, consequential, incidental or punitive losses or damages whether in contract, tort (including without limitation negligence), equity, under statute or on any other basis, and whether or not such loss or damage was foreseeable. The term "consequential damages" shall include, but not be limited to, economic loss including loss of actual or anticipated profits, business interruption, loss of use, revenue, reputation, and/or data, increased cost of working, loss or damage to equipment or other property, and liabilities of Purchaser to its customers or third persons. The owner of the products at all times is responsible for the correct operation, maintenance and servicing of the pump unit as prescribed in this manual. To establish that the products have been serviced and maintained as per the supplied instructions, the owner is required to provide a complete service history in writing for the pump unit. Refer to the maintenance schedule and maintenance checklists in this manual. Failure to comply with these requirements could result in the warranty being void as a whole. If a defect is detected with the pump unit, it is the responsibility of the owner to take appropriate action to stop using the pump unit and/or decommission it. The defect must be reported to the supplier or the manufacturer directly. It is recommended that the owner documents evidence in regards to the date in which the defect has been reported. Refer to field observational checklist. Furthermore, warranty claims can only be considered and approved by a Weir Minerals Australia representative. For further information on warranty and warranty claims please contact the supplier of the pump unit or the manufacturer directly. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 10 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Technical Data 3 Technical Data UNIT This section presents technical descriptions and specifications for the pump unit. 3.1 Pump Unit Data Table 3-1 lists the pump data for the unit. Table 3-1: Pump Data Unit Model: MEFP-420HV Electric Pontoon Pump Unit Motor: WEG 400kW 3 Phase 6 Pole 50 Hz Bare Shaft Pump: MF-420HV 10/6 FG005M Drive: Belt Drive Speed Ratio: 1.06 Down Priming System: 30 deg Flood Primed Discharge Flange: DN200 ANSI 150 Pump Unit: 16,480 kg Revision: 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 11 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Technical Data Table 3-2 lists the pump data for each pump cassette. UNIT Table 3-2: Pump Data – Pump Cassette ® Pump Designation: Multiflo MEP-420HV Motor: WEG 3 Phase 6 Pole 60 Hz IP56 Power: 400 kW RPM: 1200 rpm Motor Serial Number: N/A Motor Frame Size: 400 J/H Motor Mass: 3,060 kg Bare Shaft Pump: Multiflo MF-420HV Bare Shaft Pump Serial Number: 5872 Bearing Assembly Serial Number: 6206 Bare Shaft Pump Material: H7A Impeller Material: A05 Impeller Diameter: 750 mm Number of Vanes: 4 Minimum Passage Size: 50 mm Shaft Material: E05 Bare Shaft Pump Mass: 2,247 kg Belt Drive: SPC5300PGAT Predator (5-off) Pulley Driver: SPC-530-5-4535 Pulley Driven: SPC-560-5-4535 Cassette Mass: 7,279 kg Revision: 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 12 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Technical Data Pfrac UNIT Figure 3-1: Pump curve Note: This pump curve reflects the pumps performance from the suction flange to the discharge flange of the pump only and does not include any losses for suction restrictions or valves and pipework on the discharge. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 13 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 3.2 Technical Data Manufacturer and Product Information The Multiflo® pump unit is provided with Equipment Identification which contains the following information. Model Number Job Number Mass – wet and dry Serial Number Any specific instructions related to the manual if applicable The Multiflo® pump unit is also provided with tags that contain information such as greasing cycles on the bare shaft pump, startup procedures, and shutdown procedures if applicable. Pump unit and bare shaft pump technical data is provided in the subsequent sections of the manual. NOTE: Information for this pump unit can be found under Technical Data Section of this manual. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 14 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 4 Pump Unit Description Pump Unit Description This section describes the product, its basic working principle, and basic details about its functional components. 4.1 Environmental Conditions The Multiflo® pump unit is of a robust construction and is designed to operate and sustain operation in harsh weather conditions. The pump unit can operate effectively in ambient temperatures between 0 0C and 45 0C. Rain will not affect the normal operation of the pump unit. 4.2 Major Components The Multiflo® MEP-420HV pump unit is a cost effective pumping solution which consists of pontoon mounted pump unit. The unit is flood primed, electric motor driven pump unit. An electric motor is the main drive unit. Assembly, operation, and maintenance of all the major components are explained in subsequent sections. Appropriate safety, assembly and installation instructions, and references are provided throughout the manual. It is the user's responsibility to read and follow these instructions before/during any assembly, installation, operation, and maintenance procedures. Positive pump priming is critical to the reliability of a pump unit. Multiflo® pump units are designed to ensure that the pump is always primed. Pump Cassette Assembly Pontoon Assembly Discharge Assembly Figure 4-1: Major components of MEP-420HV pump pontoon Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 15 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Pump Unit Description 4.2.1 Electric Motor The Multiflo® pump unit is integrated with a WEG 400 kW 6 pole electric motor. The WEG electric motor which drives the bare shaft pump generates 400 kW@1200 rpm and is the main source of power. NOTICE Refer to the accompanying manual “WEG Electric Motor Manual" for further information on the motor. 4.2.2 Bare Shaft Pump The 10/6 FFG 420HV pumps with enlarged suction are specifically designed for continuous running in dirty water and mild slurry applications where ordinary water pumps are not suitable. Acidic water found in many mine water runoff situations can also be handled. The impeller cast from A05 is specially designed to obtain high efficiencies without requiring close clearances between impeller and casing, and still maintain the ability to pass reasonable sized solids. The long wearing materials, the bare shaft pump is cast from have been developed for abrasion and corrosion resistance and to give a long life in slurry pumping applications. Figure 4-2: Bare shaft pump Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 16 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Pump Unit Description Volute Stuffing Box Impeller Cover Plate Frame Plate Figure 4-3: Bare shaft pump wet end parts Shaft End Cap Grease Nipple Roller Bearing Bearing Housing Roller Bearing Figure 4-4: Bearing assembly Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 17 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Pump Unit Description 4.2.3 Drive Belts The pump unit is fitted with v-belt drive. This allows quick and easy setup of the pump and eliminates the possibility of pump misalignment. NOTICE Refer to the accompanying manual for more information on belt drives. 35.0 – 90.0 mm Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. 18 mm – 127 mm Page 18 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 4.3 Pump Unit Description Centre of Gravity and Mass Figure 4-5: Pontoon assembly centre of gravity Assembly Mass Pontoon assembly mass Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 16,480 kg UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 19 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5 Transport & Storage Transport and Storage This section addresses information relating to the transport and storage of the pump unit. 5.1 Transport To prevent liquids from leaking and causing dangerous situations during transport of the pump or pump unit, the following precautionary measures must be taken: Disconnect the discharge pipes from the pump. If an external fuel tank was used, the fuel lines from the external tank must be disconnected. Take necessary measures to capture all draining fuel. Drain any liquid that is present in the pump or pump unit. Flush the pump or pump unit. Contact Multiflo if you have any questions or concerns. 5.2 Transportation Safety The transport vendor must pack the freight such that it: Ensures any instructions required to lift or re-tether the load are fully visible. Does not cause any hazard to the supply staff, transport personnel, and the generic public. Complies with all legal requirements including mass, dimension and load restraint requirements. Can withstand high-speed road transport over rough terrain. Can be safely loaded/unloaded from the transport vehicles. Minimises the risk of injury to all personnel involved in the freight transportation. Minimises the risk of damage to the freight. Minimises the risk of damage to other freight and the general public. Has packing labels that specify the weight of the items and details of the recipient. Have adequate protection under ratchet-strap tie-downs placed over painted areas to minimise paint damage. Secures the loose items. 5.3 Chain of Responsibility Under COR regulations, all parties with some control in the supply chain have legal responsibilities to ensure compliance with relevant heavy vehicle road laws, including mass, dimension and load restraint laws. This includes people involved in consigning, loading, packing, and receiving freight as well as drivers of those vehicles (for example, in relation to speeding and fatigue management). Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 20 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5.4 Transport & Storage Load Restraint The securement systems must withstand the forces associated with the following four deceleration/ accelerations, applied separately. Figure 5-1: Load restraint Key requirements for load security are: 1. Ensure that the load platform, bodywork, and any load securing equipment are in a serviceable condition before loading the vehicle. 2. Secure the cargo such that it cannot shove away, roll-over, wander because of vibrations, fall off the vehicle, or make the vehicle tip over. 3. Determine the securing method(s) best adapted to the characteristics of the cargo (locking, blocking, direct lashing, top-over lashing, or a combination of these). 4. Ensure that the vehicle and blocking equipment manufacturers’ recommendations are adhered to. 5. Ensure that the cargo securing equipment is commensurate with the constraints it encounters during the journey. Ensure that the securing equipment can withstand the following conditions, which are considered as normal circumstances that may occur during journey: o Emergency braking o Strong cornering to avoid an obstacle o Bad road or weather conditions 6. Inspect the cargo and check for overload and/or poorly balanced weight distribution before starting when cargo is loaded, unloaded, or redistributed each time. Ensure that the cargo is distributed in such a way that the centre of gravity of the total cargo lies as close as possible to the longitudinal axis and is kept as low as possible (heavier goods below, lighter goods above). 7. Use equipment which supports the cargo securing such as friction mats, walking boards, straps, edge beams, etc. wherever possible. 8. Ensure that the securing arrangements do not damage the goods transported. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 21 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5.5 Transport & Storage Load Restraining Tools The basic safety principles related to the load restraint tools are: The securing of any pump must be undertaken by a qualified and experienced person who is familiar with applicable safety and transportation legislation, site requirements, and best practices. This person must be able to assess the load, create a plan, and then apply it safely. Inspect tensioners, chains, straps, and other restraint mechanisms regularly, to make sure that they are suitable to secure the proposed load. Do not use ropes or over-centre load chain binders (dogs) (refer to Figure 5-2), when you secure loads for collection or delivery from Weir Minerals Division. Figure 5-2: Over-centre load chain binder 5.6 Pump Unit Packing and Delivery Each order or shipment is double checked before leaving the factory. All parts, pieces, and components are listed item by item on our packing list, which accompanies each order. The number and description of each item, package, container, etc., is listed on the bill of lading. IN SIGNING THE BILL OF LADING, THE CARRIER ASSUMES FULL RESPONSIBILITY FOR SAFE DELIVERY OF ALL GOODS TO DESTINATION IN THE SAME ORDER AS TENDERED BY THE SHIPPER. In the event of damage or shortage, have the transportation company note the same on the freight bill. A packing list is attached to the shipment for the items contained. Check each item against the list. Check by description, item/tag no., document reference, quantity, etc. Should there be any discrepancies, notify Weir Minerals Australia immediately. Small parts and items such as bolts, washers, bushings, and keys are just as important to an installation as the larger parts. Make sure these are located and checked before disposing of any containers or packing equipment. Weir Minerals Australia is not responsible for the loss of items that are listed and included on our packing list. NOTICE Illustrations used are only suggestive. Not actual. NOTICE Refer to the detailed packing list attached with the pump unit for more details. 5.7 Packing Each shipment is sent through approved transport companies. Containers are used for overseas transport while trucks can be used for local transport. Depending on the size and number of components present, the unit can be disassembled if required and packed in suitable containers. The components are packed in such a way so that the integrity of the components is not damaged during shipment. Heavier components are left free standing in the truck/container. However, timber or any suitable equipment may be used to prop them. These structures will sometimes be steel strapped to the base of the vehicle if required. Smaller items are bundled with nylon ropes or similar binding material or packed with appropriate packing material such as dunnage or timber in wooden crates. The wooden crates are sealed using duct tape or nylon tape. The wood packing material used on pump unit is heat treated. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 22 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5.8 Transport & Storage Receiving Upon arrival, ensure to carefully check the pump or pump unit for any signs of defects or damages that may have occurred during transport. Check the bill of lading and certify to match with the shipment. If any damage is observed or incomplete shipment, report immediately to the transporter. The transporter must immediately note this on the shipping documentation. 5.9 Loading and Unloading The pump unit is loaded onto the truck/container using appropriate lifting equipment. Consideration is given to the mass, dimensions of the unit while selecting the lifting equipment. Use only designated lifting points while lifting the components. The wooden crates and smaller components are loaded using a fork lift. Consider dimensions and mass while selecting a suitable fork lift. The user must unload the components using appropriate lifting & unloading procedures and equipment. The pump unit dimensions and mass are shown in the technical data. After unloading, strapping tape on the crates can be removed using appropriate cutting equipment. 5.10 Reporting Shipping Shortage If you did not receive all the goods that you ordered and present on the packing list, do the following: Check the number of items listed on the packing list. If the number of pieces listed is greater than the number of pieces received, contact the carrier concerning the missing piece. Carefully check the packing material and container to ensure that you did not overlook the missing item. If you cannot find the item, please notify Multiflo® immediately. 5.11 Storage Recommendations after the Pump Unit is Assembled If the assembled pump unit is to be stored prior to use, it must be stored in vibration and shock free conditions. 5.12 Repacking If the pump unit components have to be transported again, the user must repack the unit in a similar manner as it was received. Appropriate packing, loading, lifting, and transport procedures must be followed so as not to damage the integrity of the components. Multiflo® does not bear any responsibility if any pump unit components are damaged during repacking and transport. 5.13 Fire Suppression and Fire Extinguishers Fire suppression systems are tested and certified during OEM production, it is a maintenance requirement for the system to be inspected every 6 months. Current certification of the fire system needs to be checked during assembly and commissioning. If the system certification is out of date, inspect on and complete the re-certification before putting the unit into service. Fire extinguishers are supplied without current certification and need to be tested and tagged prior to the machine being operated. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 23 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Transport & Storage 5.14 Pump Unit Lifting and Moving 5.14.1 Preparation for Lifting The guidelines listed below must be carried out prior to lifting pump unit. Follow steps mentioned in the ‘Assembly and Installation section’. i. Ensure the pipes or hoses are disconnected from the wet end pump discharge. ii. Remove/secure any loose items of pump hardware, such as clamps, connectors, lengths of pipe etc. that may be lying around the deck. iii. Connect appropriate lifting chains/straps to the main lift point of the unit. iv. If ground is excessively rough, have it levelled first. v. Lifting and locating should be done at a safe speed. 5.14.2 Lifting Instructions for Pump Unit Four lifting eyes are integrated on the centreframe of the pontoon, these are for lifting the complete pump unit. Four lift eyes are integrated into the pump cassette frame, these are for the lifting of the cassette only. All major lifting eyes are painted pink. For more information on lifting of pontoon, walkways, and other components, refer the ‘Assembly and Installation Section’. CAUTION Qualified and experienced personnel only should undertake lifting the pump unit. Refer to site procedures for lifting, personnel, and equipment requirements. Only use certified lifting equipment with an adequate lifting capacity and always lift directly above. Lifting from an angle can lead to dangerous situations. Appropriately, authorized personnel may only perform lifting work. Neither the lifting eye on the electric motor nor the lifting eye of the pump may be used for transport of the pump unit. Always disconnect all connections before moving the pump unit. Never walk under a raised load. This can result in a life-threatening situation. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 24 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Transport & Storage Four point lift only – Pontoon assembly lift only Figure 5-3: Pontoon assembly lifting points Figure 5-4: Pontoon tow points Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 25 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Transport & Storage 5.14.3 Moving Instructions for Pump Unit The pump unit can ONLY be lifted from the integrated lifting eyes. Refer to the lifting instruction for pump unit section for further information. NOTICE If pontoon is to be lifted into position, gantry and some handrails will need to be removed. If pontoon is to be pushed into position, gantry, pump cassettes and first section of discharge pipework some will need to be removed. CAUTION Always disconnect all connections before moving the pump unit. Do not move the base by towing, pushing or pulling under any circumstances. 5.15 Storage It is the responsibility of the purchaser to store the equipment of supplied items prior to use. The pump unit and any associated equipment must be stored in a manner which will not interfere with the integrity of the equipment whether through exposure to an unsuitable environment, undue rough handling and onsite transportation or the loss/damage of equipment components. Upon receipt of the pump unit, it should be sheltered to minimise exposure to the elements. The shelter must provide a dry, vibration, shock-free and dust free environment. Avoid humidity. All electrical components must be stored in a dry, damp - free and dust free environment. All electrical components must be properly enclosed in a crate or any suitable packing material. Ensure adequate ventilation is provided when electrical components are stored and ventilation openings are not obstructed. THE PURCHASER ASSUMES FULL RESPONSIBILITY FOR THE PUMP UNIT ASSOCIATED EQUIPMENT WHEN STORED, HANDLED, AND TRANSPORTED ONSITE. AND ANY CAUTION Ensure that the enclosure of any electrical component physically prevents contact with live circuits. Carry out regular checks to ensure that the product is in good condition. 5.15.1 Short Term Storage (<12 Months) Take following measures, if storage is less than 12 months: 1. As much as possible, store the pump unit in a location that minimizes exposure to the elements. 2. Every thirty days, rotate six full rotations of the motor and pump shafts by hand. 3. Remove or disable Electro-Luber grease dispensers, change or re-enable, prior to returning unit to regular service. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 26 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Transport & Storage 5.15.2 Long Term Storage (>12 Months) Take following measures, if storage is greater than 12 months: 1. Seal both the suction flange and discharge flange liquid-tight. 2. Seal breather, dipstick tube and all other openings with waterproof tape. 3. Grease exposed members subjected to corrosion. 4. Every thirty days rotate six full rotations of the pump and motor Shafts by hand. 5. Remove or disable Electro-Luber grease dispensers, re-enable dispensers before returning Unit to service. 5.15.3 Inspection during Storage Inspect pump unit during storage for any evidence of electric motor fluid leaks, lubrication leaks, or electrical wiring damage. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 27 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6 Assembly & Installation Assembly and Installation This section describes all facets of how the pump or pump unit is to be installed and assembled. 6.1 Safety Notes during Assembly DANGER Qualified and experienced personnel only should undertake lifting the pump unit. Refer to site procedures for lifting, personnel, and equipment requirements. Only use site approved lifting equipment. Follow general arrangement drawings during assembly and installation. CAUTION IT IS THE USER'S RESPONSIBILITY TO ENSURE THAT NO COMPONENTS ARE DAMAGED DURING ASSEMBLY AND INSTALLATION PROCEDURES. Installation to be carried out on level flat ground and by trained personnel only. NOTICE The graphical descriptions are intended as a guide only. Some of the instructions may contain information & illustrations regarding the installation of items not specifically for use of this pump unit. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. WARNING Do not stand under suspended loads. DANGER Do not place any part of your body under suspended loads. NOTICE Always use anti-seize on all bolt threads before tightening the bolts. When all bolts holes are aligned, insert bolts, and tension. NOTICE Refer to the "Tightening Torque Values" in the appendix section of this manual for torque values. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 28 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6.2 Assembly & Installation Safety Notes during Installation and Moving CAUTION Pump unit to be moved by qualified and experienced personnel only. USE DESIGNATED LIFT EYES ONLY. Carefully lift and locate all the components. Do not drag on rugged terrain. All assembly and installation is to be performed on solid level ground. Pump unit to be locked out, tagged out and tested for dead before any maintenance or service is performed. NOTICE Pump unit moving and locating instructions are intended as a guide only. Site preparation and positioning are to be undertaken with regards to site conditions and procedures. Pictures used to illustrate the various procedures are not actual, only a guide. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. 6.3 Space Requirements CAUTION Ensure a minimum of six metres of free space around the unit before performing any procedures. 6.4 Pre-installation This section describes all the pre-installation information and tasks required prior to installing the pump or pump unit. 6.4.1 Pre-installation Checks Before carrying out any installation procedures, please check the following: 1. No damage has occurred to the pump unit or any of its components during transport of the unit or its handling. 2. All the mechanical and electrical connections remain undamaged. 3. Contact Weir Minerals Australia customer services for any queries. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 29 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.4.2 Pump Site Preparation Proper pump site preparation is important. It should provide a good approach for the final positioning of the pump and allow access for service vehicles. Before preparing the pump site, consider the best pumping location, with the aim at positioning the pump as near as possible to the deepest part of the water catchment area. 6.4.3 Moving and Locating the Pump Unit High lift skid and pontoon suitability must be assessed by the user if the high lift skid or pontoon is not supplied by Weir Minerals Australia specific to the unit fitted to it. It is the user's responsibility to identify appropriate lifting equipment based on the site and terrain conditions. The mass and centre of gravity of the unit should also be taken into consideration. Lifting the unit must be done using only the four designated lifting eyes. Before preparing the pump site, consideration must be given to the best pumping location, with the aim at positioning the pump as near as possible to the deepest part of the water catchment area. Perform all assembly and installation procedures on LEVEL GROUND. NOTE: For further information regarding correct lifting procedures, please refer to lifting instruction which is located in lifting instruction for pump unit section of this manual. NOTICE Refer to the technical data section of this manual for further information on pump unit mass and dimensions. 6.4.4 Pipework Attachment CAUTION Misalignment of pipework and other mechanical connections to the pump assembly could cause vibration and potential failure of the piping or pump housing causing projectile hazards or an uncontrolled release of pressure. Inappropriate torqueing of flanges may cause damage to flange/gasket and sudden release of projectiles and liquid under pressure. When installing pipework onto the suction and discharge, pipe loading on the pump may crack the case and lead to sudden release of projectiles and liquid under pressure. 6.4.5 Confined Spaces A confined space is determined by the hazards associated with a set of specific circumstances and not just because work is performed in a small space. A confined space means an enclosed or partially enclosed space that: Is not designed or intended primarily to be occupied by a person; and Is, or is designed or intended to be, at normal atmospheric pressure while any person is in the space; and Is or is likely to be a risk to health and safety from: An atmosphere that does not have a safe oxygen level, or Contaminants, including airborne gasses, paint fumes, vapours and dusts, that may cause injury from fire or explosion, or Harmful concentrations of any airborne contaminants, or Engulfment. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 30 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.4.6 Hazards Entry into confined spaces can be very hazardous. Unless proper training, equipment, and procedures are in place, entry into confined space/confined spaces must be restricted. A worker is considered to have entered a confined space just by putting his or her head across the plane of the opening. The confined space may contain toxic gases. Workers who are simply near the opening may be at risk. Often the toxic gases are under pressure because of heat inside the confined space or when gases are generated inside the space. As a result, the concentration of toxic gases near the entrance to the confined space can be high enough to cause death. Similarly confined space/confined spaces may pose hazards such as oxygen deficiency, toxic atmospheres, physical hazards etc., if the space is accessed without proper safety measures. It is the user's responsibility to fully understand the risks and consequences of operation in confined space/confined spaces and adhere to all the regulations, necessary precautions, requirements, and laws pertaining to operation in such spaces. CAUTION Explosive gases and paint fumes might be trapped in confined spaces. Do not weld on or near pontoon floats. 6.4.7 Identification of Confined Spaces It is vital to identify all confined spaces in any workplace. The Multiflo® dewatering pump unit has all the confined spaces tagged with warning symbols. These areas must be secured against entry and all necessary assessments must be done by a qualified person familiar with the confined space conditions and the work to be done in that space. All the necessary precautions and measures MUST be undertaken while making these assessments and consequent operations in such a place. The flotation hulls on the pump unit is treated as confined space/confined spaces. The sealed access covers are access to this space and are identified as such as per the diagram below. All necessary precautions, assessments and regulations must be complied with during assembly, installation, operation and maintenance procedures. Figure 6-1: Confined space warning signs Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 31 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.4.8 General Placement of the Pump Note: Because there are many different versions of the pump unit available, only the general instructions are provided. See the specification sheet for the particular pump unit for technical data. Contact Weir Minerals Australia if you have any questions and concerns regarding this matter. The pump unit must be placed on a flat surface capable of supporting the load. The user must also ensure that the pump unit is placed in such a manner that it is not subjected to any distorting forces along with ensuring that the pump has sufficient space around it in order for safe operation and maintenance activities. Follow the provided guidelines. Weir Minerals Australia is not accountable for any accidents and damage as a result from failure to follow guidelines in this manual. Misuse will result in forfeit of the right to assert any warranty or damage compensation claims. Note: If the unit is to be placed in an area prone to land slip, a full assessment on strata stability must be completed before positioning the pump. DANGER Failure to follow the guidelines for use of the pump unit in a potentially flammable or explosive atmosphere can create an extremely dangerous situation. 6.4.9 Placement in an Area with Potentially Flammable or Explosive Atmosphere Do not place the standard pump unit in a potentially flammable or explosive atmosphere, as the pump unit is not suitable for this type of environment. In some cases, where it is deemed necessary to do so, Weir Minerals Australia must be consulted and implementation of the prescribed measures must be carried out accordingly. A written approval may be provided by Weir Minerals Australia for use of the pump or pump unit in the specified situation. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 32 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.4.10 Safety Notes during Assembly DANGER Qualified and experienced personnel to lift the pump unit. Refer to site procedures for lifting, personnel and equipment requirements. Only use site approved lifting equipment. Follow general arrangement drawings during assembly and installation. CAUTION IT IS THE USER'S RESPONSIBILITY TO ENSURE THAT NO COMPONENTS ARE DAMAGED DURING ASSEMBLY AND INSTALLATION PROCEDURES. Installation to be carried out on level flat ground and by trained personnel only. NOTICE The following graphical descriptions are intended as a guide only. Some of the instructions may contain information & illustrations regarding the installation of items not specifically for use of this pump unit. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. WARNING Do not stand under suspended loads. DANGER Do not place any part of your body under suspended loads. NOTICE Always use anti-seize on all bolt threads before tightening the bolts. When all bolts holes are aligned, insert bolts and tension. NOTICE Refer to the “Spare Parts List" in the appendix section of this manual for a complete list of spare parts. Refer to the "Tightening Torque Values" in the appendix section of this manual for torque values. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 33 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.4.11 Safety Notes during Installation and Moving CAUTION Pump unit to be moved by qualified and experienced personnel only. USE DESIGNATED LIFT EYES ONLY. Carefully lift and locate all the components. Do not drag on rugged terrain. All assembly and installation is to be performed on solid level ground. Pump unit to be locked out, tagged out and tested for dead before any maintenance or service is performed. CAUTION Do not tow or push the unit unless it is fitted to a high lift skid or pontoon. NOTICE Pump unit moving and locating instructions are intended as a guide only. Site preparation and positioning are to be undertaken with regards to site conditions and procedures. Pictures used to illustrate the various procedures are not actual, only a guide. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. 6.4.12 Space Requirements CAUTION Ensure a minimum of six metres of free space around the unit before performing any procedure. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 34 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6.5 Assembly & Installation Assembly 6.5.1 Discharge Components Assembly The discharge flange of the BSP marks the discharge end of the pump. Connect discharge components starting from the discharge flange. NOTICE It is user’s responsibility to correctly assemble and install the discharge components to the non-return valve. NOTICE Refer to pipe guidelines section of this manual for further information on discharge components. CAUTION Experienced personnel to undertake lifting of the pump unit. Do not place any part of body under suspended load. Do not attempt to insert bolts until pump base is sitting on level ground and is not suspended by lifting equipment. 6.5.2 Pre-assembly Checklist Pre-assembly and Facility Observations: Ensure a specific SOP/risk assessment is compiled for any operation with consideration to the specific steps associated with this assembly as detailed in this document. All assembly procedures are to be carried out on flat level ground only. If ground is excessively rough, have it levelled first. Ensure that there is sufficient space around the pump unit to work around (recommended 6 m minimum). Necessary arrangements to be made to provide safe working conditions as per onsite procedures and local laws. Close the assembly area to all traffic. Temporary movable roadblocks, warning and information signs to be installed and a sentry to control access as required. Demarcate parking areas for equipment and vehicles to remove possible interference with pedestrian traffic and machinery operation. Keep the assembly work area as clean as possible. Ensure signage and barricading is appropriate near pump unit to prevent serious to fatal injuries to employees working on the unit. All lifting operations must be undertaken only after giving consideration to the mass and dimensions of the components. All safety equipment, tools and necessary accessories for performing assembly procedures MUST be accessible and in a serviceable condition before commencing assembly procedures. Trained personnel to carry out all procedures. If necessary, training must be provided to person/persons handling the assembly procedures. All procedures MUST be carried out in accordance to local laws and local environmental regulations. When unloading the pump unit components employ appropriate lifting techniques and position the components at the appropriate site for assembly. Prior to assembly, remove any surface rust or debris from all the threaded holes. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 35 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.6 Assembly of Pontoon 1. Fit the strainer to the suction end of the BSP fitted to the centreframe. Suction Strainer Figure 6-2: Fitting strainer to BSP 2. Fit the handrails and kickplates to the centreframe. Figure 6-3: Fitting handrails and kickplates to centreframe Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 36 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 3. Assembly & Installation Fit the gate assembly, handrails, and kickplates to the LH float of the pontoon. Figure 6-4: Fitting handrails and kickplates to RH hull 4. Fit the gate assembly, handrails, and kickplates to the LH float of the pontoon. Figure 6-5: Fitting handrails and kickplates to LH hull Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 37 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 5. Assembly & Installation Assemble the LH float to centreframe as shown in the figure below. Right and left floats have to be assembled to the centreframe. Figure 6-6: Assembly of LH float Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 38 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6. Assembly & Installation Centreframe and floats have three bolting arrangements as shown in Figure 6-7 and Figure 6-8. LH Float and centreframe have to be bolted as shown in Figure 6-7, insert bolt into the holes of the brackets welded on both float and frame, and fasten with nut along with two flat washers and one spring washer. The LH float and centreframe have to be secured at front and rear ends of the pontoon assembly at the lift points as shown in Figure 6-7, using six set of bolts, nuts and washers. . Figure 6-7: Assembly of LH float Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 39 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7. Assembly & Installation The float and frame assembly has to be secured at the underside of the frame as shown in Figure 6-8. The bolt and nut along with washers have to be fastened to the welded brackets as shown below. There are two such brackets on the float hull and the frame, totalling to four for the entire pontoon. Figure 6-8: Assembly of LH float Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 40 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8. Assembly & Installation Assemble the RH float hull to the center frame with similar steps followed in the assembly of the LH float and center frame. Figure 6-9: Assembly of RH float 9. Fit the pontoon stairs to the LH float and RH float as shown in the image. Figure 6-10: Assembling pontoon stairs Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 41 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 10. The assembly of discharge section to be done onsite and assembled to the outlet of the pump as shown below. 11. Firstly, the steel discharge pipe spool fitted with air release valve has to be fitted to the outlet of the bare shaft pump. Ensure the discharge pipe clamp is fitted to the cassette frame. 12. Fit the check valve followed by a spool to the discharge pipe spool, using the discharge pipe support clamp fitted to the centreframe. Ensure the adapter and ball valve is fitted to the spool. 13. Now fit the butterfly valve to the spool along with the steel discharge pipe spool. A discharge pipe support clamp fitted to the centreframe secures the steel discharge pipe. Air Release Valve Discharge Pipe Spool Discharge Pipe Spool Butterfly Valve Check Valve Discharge Pipe Support Clamp Ball Valve Discharge Pipe Spool Figure 6-11: Discharge assembly Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 42 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 14. Assembly & Installation Image below clearly shows the discharge assembly fitted to the unit using discharge pipe support clamps. Figure 6-12: Assembling Discharge assembly Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 43 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 15. Assembly & Installation Fit the ladder tray assembly to the pontoon unit. There are four bolting points on the RH float to fit the ladder tray assembly. Figure 6-13: Assembly of ladder tray Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 44 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 16. Assembly & Installation Place the motor on the motor mount plate and firmly fasten eight bolts and nuts along with its washers. The position of the motor can be adjusted using eight studs-nut assembly mounted on the mount plate. Electric Motor Figure 6-14: Assembly of motor Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 45 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 17. Assembly & Installation Fit the two belt guard back plates to the pump cassette guard mount bars. Belt Guard Back Plate Figure 6-15: Fitting belt guard back plate 18. Fit the motor pulley along with its taperlock bush to the shaft of the electric motor. Taperlock Bush Motor Pulley Figure 6-16: Assembly of motor pulley Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 46 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 19. Assembly & Installation Fit five belts connecting motor pulley and bare shaft pump pulley. Refer section 7.2.5 for information on bumping the motor. Belts Figure 6-17: Fitting belts 20. Fit belt guard-cover assembly, and fasten all screws. Belt Guard-Cover Assembly Figure 6-18: Fitting belt guard-cover assembly Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 47 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 21. Assembly & Installation Fit both the life rings on to the handrails as shown below. Life Ring Figure 6-19: Fitting life ring assembly 22. Fit the connection box to the pontoon as shown in the image below. Figure 6-20: Fitting connection box Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 48 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.6.1 Preparation for Lifting The guidelines listed below must be carried out prior to lifting pump unit. 1. Ensure the pipes or hoses are disconnected from the pump discharge. 2. Remove/secure any loose items of pump hardware, such as clamps, connectors, lengths of pipe etc. that may be lying around the deck. 3. Connect appropriate lifting chains/straps to the main lift points of the base. CAUTION Pump assembly to be lifted by experienced personnel only. Pump assembly to be connected to a crane and must be lifted using the lifting lugs provided on the pontoon. Suitability of lifting apparatus to be determined according to local site requirements. All assembly and installation is to be performed on solid level ground. Base mounted pumps must only be lifted, and not pushed or towed. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. Pump unit lifting and locating instructions are intended as a guide only. Site preparation, unit lifting and positioning are to be undertaken with regard to site conditions and procedures. Under no circumstance should any pump unit be pushed or towed unless the unit is fitted to a high lift skid or pontoon. While lifting the pump using an overhead crane, use appropriate length of chains to avoid the unit from tilting. Use spreader bars if necessary. Use only designated lifting lugs to hoist the unit to prevent damages to the structure. Figure 6-21: Lifting the unit with chains Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 49 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 6.7 Assembly & Installation Positioning 1. Ensure that a suitable pump location is established which will provide a good approach for final positioning and safe access for electricity and service vehicles. 2. Pump should be lifted using a designated crane to a required position. 3. The equipment operator and person directing must be clear on the hand signals being used by the person directing. Pontoon mounted pumps must only be pushed on the push beam assembly provided. 4. Ensure the pipes or hoses are disconnected from the wet end pump discharge. 5. Stow any loose items of pump hardware, such as clamps, connectors, lengths of pipe etc. that may be lying around the deck. Final positioning will usually involve pushing the pump unit down a ramp at a maximum grade of 10°, either with the dozer blade or the excavator bucket. Under no circumstances should pump unit be pushed on its sides or at the suction end (rear). Before positioning a pontoon mounted pump, consideration should be given to the best method of connecting up the discharge line. (It is extremely difficult to connect up hoses and pipes in deep water). If lay flat hose is to be connected to the initial discharge pipe, then this connection can be made before the pump is launched. If poly pipe is used, one or two lengths can be connected to the pump discharge before positioning. NOTICE Do not push the unit on its sides or at the suction end (rear) under any circumstance. CAUTION Caution when positioning the pump unit. The maximum permissible tilt at which the pump unit can be placed is at 10°. Positioning the pump unit above this angle of inclination might affect the performance of the pump unit or cause damage to the components. If the pump unit is operating at a 10° tilt, it is the operator/user’s responsibility to ensure that the pump unit is at a stable condition. It is the operator/users responsibility to make the judgement in regards to whether the pump unit needs to be tied down (using tie down points) to ensure a stable and safe operation. NOTICE Do not push the unit on its sides or at the suction end (rear) under any circumstance. 6.7.1 Removing 1. Ensure discharge pipes are disconnected from the unit. 2. Remove any loose items of pump hardware, such as clamps, connectors, lengths of pipe, tools, etc, that may be lying around the deck. 3. Manoeuvre the pontoon close to the shore. 4. Remove the discharge pipe from the discharge flange at the edge of the pontoon. 5. Attach the chains to the lifting vehicle. 6. Slowly lift the unit from the water. NOTICE Do not push the unit on its sides or at the suction end (rear) under any circumstance. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 50 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation CAUTION Exercise caution when positioning the pump unit. The maximum permissible tilt at which the pump unit can be placed is at 10°. Positioning the pump unit above this angle of inclination might affect the performance of the pump unit or cause damage to the components. If the pump unit is operating at a 10° tilt, it is the operator/user’s responsibility to ensure that the pump unit is at a stable condition. It is the operator/users responsibility to make the judgement in regards to whether the pump unit needs to be tied down (using tie down points) to ensure a stable and safe operation. 6.7.2 Installation Checks NOTICE Most units are assembled, aligned and test run at Weir Minerals Australia factory before they are despatched. This alignment may be affected during transportation, therefore should be checked before the unit is used on site. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 51 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.7.3 Pipe Guidelines If pipe connections need to be used the selected pipes must comply with the following guidelines: The diameter and length of the selected suction pipes and discharge pipes along with any other additional components such that the inlet pressure remains above the minimum allowable value. The operating pressure must not exceed the maximum allowable value. A system resistance curve needs to be plotted on the pump performance curve to attain the correct duty point for the system. The pipe diameter needs to be equal to or greater than the sizes of the pump’s discharge. Use the largest diameter possible to maintain minimum velocity. Align the pump’s pipe connection flanges. The flanges of the pipes must be able to connect with the pump without putting any parts under stress. Expansion elements must be integrated in the pipes to accommodate for any possible vibration and/or hot liquids environments. The pipes connected directly to the pump must be supported as the weight of the pipe along with the fitting may not be supported by the pump. The discharge pipe must be fitted with an isolation valve. This valve must be placed as close as possible to the pump allowing for isolation to cater for maintenance activities. The isolation valve and the pipe’s diameter must be similar in sizes. Install a measuring instrument (pressure and/or flow) in the discharge piping to monitor operation. If applicable, connect the pump unit to a suitable safety system. This judgement is left to the end user to specify requirements. Insulate or shield all hot pipes. Specific regulation that pertains to the suction and pressure pipe must be observed. NOTE: Pumping viscous liquid will result in significant losses in flow both in the suction and discharge pipes. Components such as shutoff valves, bends, and suction strainers that are placed in the discharge system will increase this flow loss. If the pump is used for pumping slurry, attention must be given to maintaining minimum velocity of the liquid so the solids remain suspended in the liquid and don’t settle. In some cases settled solids can partially or fully block discharge hoses or reduce pump performance. CAUTION The designer of the installation is responsible for installing the pump unit correctly. Failure to follow guidelines can results in an excessive load on the pump unit and/or piping, which can cause severe damage to the pump unit and/or piping. Possible leakage of liquid can lead to a dangerous situation. Over-pressuring could cause uncontrolled release of pressure or catastrophic component failure. Incorrect pipe selection could affect pump performance and service life. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 52 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Assembly & Installation 6.7.4 Pressure Pipe Installation of safeguards such as protection against over-pressurising is the responsibility of the designer of the installation. If there is a danger of water hammer, install either a bypass, accumulator, or a pressure safety valve in the discharge pipe. CAUTION Prevent sudden closure of valves that could cause water hammer. Over-pressuring could cause uncontrolled release of pressure or catastrophic component failure. 6.7.5 Suction Strainer A suction strainer must be installed on the suction side of the pump regardless of solid content, pH, or viscosity of the liquid being pumped. Do not operate the pump unit without a strainer. If the strainer fitted is not supplied by Weir Minerals Australia specifically for the application it must not: Have holes larger than the passage size of the pump. Have total area of the holes no less than 3X the area of the suction hose, allowances need to be made for partial blockage in this calculation. The strainer should also have provision to be inspected and cleaned. Weir Minerals Australia can be consulted for information regarding the maximum allowable particle size (solid handling capacity of the pump). CAUTION A clogged suction strainer can increase losses to the point that the NPSHa falls below the NPSHr. This will result in pump cavitation which is damaging to the pump and has a negative impact on the performance of the pump unit. Do not operate the pump without a suitable sized suction strainer. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 53 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7 Operation Operation This section describes how Multiflo® recommends the product is operated. 7.1 Operation Safety This section lists the safety guidelines to be followed while the pump or pump unit is in operation. NOTE: Ensure removal of transport tabs on mechanical seal (if fitted) prior to commencing pump operation. CAUTION Bare shaft pump and all the fluids may be at extremely high temperatures when the pump unit is stopped and may cause serious burns. Ensure pump unit has cooled before any checks or maintenance is carried out. Personal protective equipment is to be worn while operating or servicing the unit. Pump unit to be locked out, tagged out and tested for dead before any maintenance or service is performed. DANGER Ensure that there is at least six meters free space around the unit before performing any operational procedures. Trained personnel must operate pump unit. A suction strainer must be fitted to the suction hose and it should be no less than 1 meter below the surface of the water. Always use a large diameter hose for the suction, and use the correct size pipe on the discharge to obtain maximum performance from the unit. NOTICE Protective Devices: Belt guards, gland guard for pump are used as protective devices, they must be in place and secure before the unit is energized. Although the unit is capable of suction lifts of up to eight meters, it is advisable to install the pump unit as close as possible to the level of the fluid being pumped to obtain optimum flow rates. WARNING Wear PPE while moving, installing, operating, or overhauling the unit. CAUTION It is the user’s responsibility to provide appropriate safety training according to the nature of the operation. CAUTION Do not operate the pump unit while undertaking maintenance operations or while adjusting the glands. If the pump unit is operated while guards are removed, the user is exposed to rotating equipment which can lead to entanglement. The user is liable for any damages or injuries caused by operating the pump unit. Do not over tighten the gland packing, as this may result in fire and/or equipment damage. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 54 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Operation 7.1.1 Electric Motor Safety Notes NOTICE Refer to the “WEG Electric Motor Manual - Installation, Operation, and Maintenance Manual" in the accompanying manuals section for safety notes related to the electric motor. 7.1.2 Bare Shaft Pump Safety Notes NOTICE Refer the accompanying manual “MF-420HV 10/6 FFG Bare Shaft Pump IOM” for further information on bare shaft pump safety. 7.1.3 Taperlock Bushes NOTICE Refer to "Drive Belt IOM" for further information on taperlock bushes. 7.1.4 Noise and Radiation No radioactive material is used in the construction of this pump unit. Noise levels will exceed 85 dBA when the unit is operating, hearing protection must be worn within 15 m of the unit. Electric motor, pump, hydraulic and exhaust components could be at high temperatures when the unit is operating. WARNING The noise level generated by the pump unit is greater than 75 dBA up to 7 m from the pump unit. The user MUST use PPE to protect against noise. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 55 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7.2 Operation General Description and Function of the Equipment 7.2.1 Principle of Operation This type of bare shaft pump used on Multiflo® units is of centrifugal design and will not operate unless initially filled with water (primed). This unit uses flood priming to initially prime and to maintain prime as long as fluid is available. In all pumping operations, ensure that a Multiflo® suction strainer is fitted. 7.2.2 Pump Unit Orientation Pump Unit Left Side Pump Unit Rear End Pump Unit Front End Pump Unit Right Side Figure 7-1: Pump unit orientation 7.2.3 Daily Pre-start Checks DANGER Pump unit to be locked out, tagged out, and tested for dead before any maintenance or service is performed. Table 7-1: Daily Pre-start Checklist Bare shaft pump Check general condition, ensure gland guard is fitted. Mounting bolts Check electric motor, bare shaft pumps and belt guards mounting bolts are not loose or missing. Re-tighten or replace bolts as necessary. V-belts and pulleys Check condition and tighten if required or replace if necessary. Suction strainer Check the strainers for blockages or damage. Make sure that the strainer is properly submerged. Electro-Luber Check grease levels, ensure operating light is functioning. Gland adjustment Ensure the gland is adjusted to the correct position required to pump (adjust as required). Pontoon Check pontoon for unusual flotation or listing. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 56 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Operation CAUTION When adjusting the gland the pumping liquid may discharge into the environment and cause exposure to the liquid by the operator. The operator must follow site procedures for spillage of liquids and wear appropriate personal protective equipment to minimize exposure to the pumping fluid. Do not over tighten the gland packing, as this may result in fire and/or equipment damage. When adjusting the glands, possible uncontrolled release of pressure may occur and cause cutting or crushing damage to personnel. CAUTION If vibration occurs during starting, stop the pump immediately and eliminate the cause before starting again. DANGER Never allow the pump to run long against a closed shutoff valve. Otherwise, there is a danger of explosion. Heating the liquid beyond design limits can cause damage to the pump. WARNING Wear correct PPE while operating the pump. WARNING Before starting, check motor rotation direction and if it’s not rotating in the right direction change the direction of rotation. Refer section 7.2.5. 7.2.4 Starting Procedure Grease bearings of all motor as per manufacturer specifications. If the rotation of the all motor has not been checked, the motor will need to be bumped. Refer to section 7.2.5. Start the motor and test the stop button by pressing it with the palm of your hand, the motor must shutdown instantly. Start the pump and allow it to prime and pump water. Check the pumps for excessive noise, vibration, and leaks. Check the discharge for leaks. If a flow meter is attached, ensure that the correct flows are achieved and maintained. If enough water is available, monitor the unit’s performance and faults for 2 to 3 hours. If required, normal practice whenever possible is to allow pumps to operate on water only for a short period before introducing solids or slurry into the system. Test and make available any alarm signals, interlock systems, and any other protective devices incorporated in the pumping system. Ensure that the shaft seal is serviceable and flush water where required. Ensure that sufficient fluid is available at the inlet pipe to satisfactorily prime the pump. Refer to "WEG Electric Motor Manual" in the accompanying manuals section of this manual for further information on electric motor startup procedures. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 57 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Operation 7.2.5 Bumping the Motor Ensure the belts connecting motor and pump have been removed. Do not bump the motor if motor and pump are coupled. Incorrect rotation with pump and motor coupled can cause impeller to unwind from shaft and damage pump housing. With the belt guard off and the belts removed, connect the motor to the power source. Start the motor to confirm the shaft is rotating in the direction indicated in the operations section (also indicated on the cover plate of the pump). If the rotation is not in the desired direction, the red and the white phases need to be reversed. Re-check the rotation of the shaft. Fit the belts and guards as described in the operations section. Check the operating speed. WARNING Before starting, check motor rotation direction and if it’s not rotating in the right direction change the direction of rotation. Refer section 7.2.5. DANGER Incorrect rotation with pump and motor coupled can cause impeller to unwind from shaft and damage pump housing. Confirm all electrical wiring connections are secure and not exposed for possible contact with operators. CAUTION Motor must rotate in the right direction. After confirming motor are rotating in the right direction, belt guards to be fitted before putting motor into operation. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 58 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7.3 Operation Abnormal Condition 7.3.1 Cavitation Cavitation is a condition that exists when the vapour pressure of the liquid is insufficient to stop the water from changing state from a liquid to a gas. Cavitation in pumps is characterised by vibration and rattling localised at the area of cavitation, usually from the outer diameter of the volute, where the discharge transitions from the volute, changes in direction of the discharge or valving. It is important not to continually run any pump in cavitation as severe damage will occur over time, shortening the service life of the pump or components. Cavitation can be caused by: The pump being too high from the water being pumped (excessive suction lift). The electric motor RPM or pump speed is too high for the required duty. The resulting effects of cavitation are: Pitting of material surfaces. Reduction in pump performance. Damage to impeller and casing, if cavitation is severe. Figure 7-2: Result of cavitation 7.3.2 Recirculation Recirculation in the pump can be identified by excessive wear around the eye of the impeller and the throat bush of the front door. This is generally caused by excessive clearance between the impeller and the front door; it will result in decreased performance and in extreme circumstances component failure. Recirculation damage will look much like cavitation damage but will be in the low pressure area of the pump. Figure 7-3: Result of recirculation on Front Door/Throat Bush Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 59 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Operation 7.3.3 Vibration Vibration has several possible causes, most commonly debris lodged in the impeller vanes. However, bearing wear and belts deterioration may be the cause or a symptom of unsustainable operating conditions. Other causes can be but not limited to electric motor balance, loose mounting or coupling bolts, cavitation, and natural frequency harmonics. Operation of the unit with severe vibration for extended periods will result in reduced service life or component failure. 7.3.4 Severe Weather Events Pump unit mounted on pontoon requires adequate mooring to avoid abrupt movement in strong winds. Follow the below mentioned guidelines in the event of a severe weather conditions. Wind speed 20 m/s or 72 km/h 37 m/s or 130 km/h (CAT 1 wind speed) Absolute wind case Precautions Prohibit personnel presence on the pontoon. Pumping to cease. Structural integrity lost - refer to mooring load calculations. 7.3.5 Lack of Maintenance Procedures Adhere to the maintenance schedule detailed in section 8 of this IOM manual. Deviation from the procedure or service intervals without proper assessment or consultation with Weir Minerals Australia may result in catastrophic failure of components or the unit. 7.3.6 Fire Follow site specific procedures in the unlikely event of a fire. In most cases, 9 kg fire extinguishers are fitted to quick release brackets as per client requirements at the time of ordering to the unit for use on manageable fires. The electric motor should be stopped using the stop switches if it is safe to do so. Sitespecific risk assessments must be conducted to review the number of fire extinguishers and the suitability of their location. 7.3.7 Oil Leak or Spill Any oil leak from any part of the unit needs to be rectified immediately. Larger leaks or spills need to be controlled, cleaned up, and reported as per site requirements and government regulations. Oil spill booms, where required, must be maintained as per the manufacturer’s recommendations. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 60 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7.4 Operation Normal Operation Refer to site procedures for further information. 7.5 Monitoring during Operation 1. During operation, check the pump regularly for correct functioning, smooth and vibration-free running, abnormal noises, and leaks. 2. Prevent situations in which pump runs dry for more than five minutes. 3. Under optimum conditions, glands will weep if adjusted correctly. 4. The maximum permissible ambient temperature is 45 0C. The temperature of the bearings must not exceed 95 0C. 5. Ensure the pump pressure does not exceed pipeline rating (monitor pipe pressure). Note: Pumping high temperature liquids is not recommended with this equipment. CAUTION In the event of a malfunction or incorrect functioning, stop the pump. Determine and correct the cause before restarting the pump. Use the necessary personal protective equipment in the case of hot, volatile, flammable and hazardous liquids. Make sure that all the drained liquid is contained in a proper manner and disposed of in accordance with the local regulations. If there is a danger of freezing, completely drain the pump and vacuum (if present). Drain the liquid from the drip tray, if present. DANGER Lack of pressure monitoring can lead to no warning of unsafe condition, which can then lead to catastrophic failure of pump with projectile hazard. Lack of vibration monitoring can lead to failure of pump with projectile hazard. 7.5.1 Electric Motor Operation Procedures, Startup Procedures and Shutdown Procedures NOTICE For further information, refer to “WEG Electric Motor Manual - Installation, Operation, and Maintenance Manual of Motor" in the accompanying manuals section. CAUTION Electric motor will be damaged from continuous shutdown from high RPM and load. Only use the stop buttons if the situation warrants an immediate shutdown. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 61 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 7.6 Operation Draining the Pump when there is a Danger of Freezing If the pump is operating in a low temperature environment where there is a danger of freezing, the water left in the discharge can freeze compromising the integrity of some components. To avoid possible damage the liquid must be drained while the pump is at a standstill. To do so the below mentioned instructions must be followed. 1. Open the drain points. 2. Allow fluid/water to drain. 3. Close drain points. 4. Drain the discharge and the wash down hose. 5. Remove any standing water from the gland drip tray. The pump unit can only be operated to its designated design temperature range (refer to Intended Use section of this manual). Operating the pump unit in low temperatures could lead to mechanical failures in extreme cases. CAUTION Low temperature applications could lead to mechanical failure. Ensure that all the drained liquid is contained in a proper manner and disposed of in accordance with local regulations. The water must not drain directly to the ground as this could cause a slip hazard. 7.7 Monitoring of Pump Parameters CAUTION It is essential that pump parameters are monitored in the field, to avoid failure of the pump unit and associated systems. The operator must monitor the pressure and vibration to ensure correct operation of the pump unit. Opening and closing of valves must be monitored to minimise equipment damage due to water hammer/surge. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 62 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8 Maintenance Maintenance This section provides the: Safety guidelines to be followed while performing maintenance procedures. Maintenance checkpoints on the pump. Routine maintenance intervals. Maintenance procedures to be performed when components need to be inspected or replaced. 8.1 General Maintenance When maintenance is insufficient, incorrect and/or not performed regularly this can lead to malfunctions of the pump or pump unit, danger to the user, high repair costs, and lengthy breakdowns. Weir Minerals Australia is not responsible for any occurrence of accidents and damage that result from failure to follow the maintenance procedures provided in this manual. Only the operations described in this manual may be performed. Other operations must be performed by Weir Minerals Australia employees or qualified and authorised maintenance technicians. 8.2 Safety Instructions during Maintenance, Repair and Inspection Wear the right personal protective equipment. Work is only permitted on the pump when it has been locked out, tagged out, and tested for dead. For isolation procedures, follow the prescribed procedure in this manual. Protect the electric motor from unintended and unauthorised starts throughout the duration of the work activities. This can be done by isolating the batteries at the battery isolator and the discharge at the discharge isolation valve. Adhere to all instructions in regards to but not limited to handling of flammable or hazardous liquid, wearing the right PPE for the activity; smoking is prohibited, etc. when opening the pump. For further information in relation to hazardous liquids, refer or consult Material Safety Data Sheets (MSDS). Remove any guard only when the battery isolator has a personal danger lock attached by each person working on the unit Any maintenance work performed on the electrical system can only commence after the power supply has been isolated and locked and may only be performed by personnel who have been trained and authorised to do so. An exception to this would be live testing, in this instance the isolator can be energized and the starter isolator should be “OFF”, all other activities must be stopped for the duration. It is also highly recommended that all safety guards be in position before the electrical system is energized. Install protective guards when all work is completed. Use only genuine Multiflo® replacement parts or parts approved for use on Multiflo® machinery. CAUTION Multiflo® is not responsible for any damage or failures caused by fitting unauthorised or in genuine parts to any part the unit. It is the user/maintainers sole responsibility to fit appropriate components. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 63 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.3 Maintenance Isolation of Discharge Pipework When undertaking maintenance on the pump unit, take care to ensure all control measures are in place. If the discharge pipework is not isolated, discharge of the pump liquid into the environment and liquid exposure to the operator will occur. Follow appropriate site procedures for isolation and control of liquid spillages. Once the pump unit has been shutdown and isolated, the non-return valve fitted to the discharge will not isolate the discharge from the source of the pumping supply, this must be done at the isolation valve on the discharge. When servicing any pipework or associated systems, the fluid must be drained in a safe manner to ensure there is no sudden pressure release. If maintenance is to be carried out on the discharge pipework the entire discharge must be drained. There may be several pumps using the same discharge pipe, a risk assessment must be completed identifying all possible energy sources and those sources must be addressed before any work commences. CAUTION When draining pipework for servicing, discharge into the environment will take place and liquid exposure to the operator may take place. The operator must follow all plant safety operating procedures and must implement appropriate controls. Opening or closing valves of valves must be monitored to minimize equipment damage due to water hammer/surge in the pipelines. Isolation of the pump being maintained may not isolate the discharge from other sources of energy. Ensure all sources of energy are isolated before commencing work. CAUTION Disconnection of discharge line without draining may lead to an uncontrolled release of pressure. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 64 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.4 Maintenance Normal Maintenance Procedures 8.4.1 Maintenance Safety Notes DANGER Pump unit to be locked out, tagged out and tested for dead before any maintenance or service is performed. Bare shaft pump and all fluids may be at extremely high temperatures or pressures when the pump unit is stopped and may cause serious burns or injection injuries. Ensure pump unit has cooled down and all sources of energy have been isolated and dissipated before any checks or maintenance is carried out. It must be checked that the intake and discharge openings are totally isolated from all potentially pressurized connections and that they are and can only be exposed to atmospheric pressure. The pump unit is tagged with appropriate safety stickers. The user must refer the “Introduction & Safety” section of this manual to understand the safety and risks. It is the user’s responsibility to understand all the inherent risks and consequences involved during maintenance procedures and take necessary precautions against such risks. All maintenance procedures MUST be performed complying with the technical data and content mentioned in this manual. User MUST NOT perform any procedures that are not specified in the technical manual. If applicable, ensure that there is at least six (6) meters free space around the unit before performing any maintenance procedures. It is the user’s responsibility to provide the necessary training required to perform maintenance procedures on the pump unit. Look for unusual gauge readings, leaks and general condition of the unit. If a condition exists, determine the cause and have necessary repairs made. The operator must confirm hazards associated with the liquid that was last pumped before undertaking servicing or dismantling. Incorrect identification of hazardous fluids may result in exposure to potentially hazardous materials. WARNING Wear personal protective equipment when operating or servicing this unit. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 65 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Maintenance 8.4.2 Bare Shaft Pump Safety Notes DANGER The assembled bare shaft pump and the bare shaft pump individual components are heavy. Pay attention to the weight of the assembled bare shaft pump or individual components prior to lifting. Use appropriate lifting equipment to lift the pump unit or any individual pump component. CAUTION When pumps have been dismantled for complete overhaul, all parts should be closely inspected and new parts checked for correct identification. Parts being re-used should be thoroughly inspected, cleaned, and repainted where required. Mating faces and spigots should be free of rust, dirt and burrs and given a coat of grease or anti-seize before they are fitted together to assist future overhaul. NOTICE Names and basic part numbers are used in assembly instructions in this manual. Full part numbers are given in the spare parts section of this manual. Full part numbers should be used upon ordering spare parts. Always quote the serial number of the unit when ordering parts. It is preferable to renew fasteners and all threads should be coated with graphite grease before assembly. It is also recommended that all rubber seals should be replaced during major overhauls as rubber tends to harden and seals lose their effectiveness. Vibration from transport and operation can cause the loosening of some fasteners. Check and tighten. Procedures and diagrams are a guide only and should be followed in conjunction with accompanying documentation. It is recommended that all bearings, gaskets, o-rings, bushes, and nyloc nuts be replaced when rebuilding pump bare shaft assembly. Impeller adjustment is a key element in extending the wear life. Field tests on certain pumps indicate if impellers are adjusted when fitted and again at regular intervals during the operation, then an increase of 40 – 50% in life can be achieved over pumps which are not correctly adjusted. Further pumps which were regularly adjusted have shown a 20% increase in their life over pumps which were adjusted only once at initial setup. CAUTION To eliminate the possibility of brinelling of the pump and bearings, shaft-locking devices may be employed. These should be removed, and the free rotation at the pump should be checked before use. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 66 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.5 Maintenance Isolation Procedure When maintenance work is carried out on plant and equipment, a lockout procedure is required to safeguard the personnel carrying out this work. All energy sources must be isolated and stored energy dissipated before carrying out any maintenance work. Formulate and document a procedure to provide plant specific instructions for workers to follow in the lockout/tagout of equipment. Personnel must be trained in the implementation of site Isolation procedures and the correct use of tags and locks. NOTICE Formulate and document a procedure to provide plant specific instructions for workers to follow in the lockout/tagout of equipment. The hazardous energy sources must be identified and if a potential risk is apparent then measures must be taken to eliminate, isolate and dissipate the energy. There are four kinds of energy sources: Electrical energy (mains, battery/capacitor, static) Mechanical energy (transitional, rotational) Thermal energy (hot, cold) Potential energy (springs, gravity, hydraulic/pneumatic/vacuum pressure) Isolating Hazardous Energy Isolate all forms of potentially hazardous energy. Ensure that an accidental release of hazardous energy cannot occur. Make certain that entry to a restricted area is tightly controlled. Apply locks and tags to ensure that energy isolation devices remain in the “OFF” or “SAFE” position. Tags applied must be easily read, and identified. DANGER Never work on any equipment without a personal lock on each isolation point. Always confirm correct isolation before starting any maintenance procedures. 8.5.1 Electric Motor NOTICE Refer to the “WEG Electric Motor Manual - Installation, Operation, and Maintenance Manual of Motor" in the accompanying manuals section. 8.5.2 Maintenance – Bare Shaft Pump NOTICE Refer to the accompanying manual “MF-420HV 10/6 FFG Bare Shaft Pump IOM” for further information on bare shaft pump safety and maintenance procedures. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 67 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.5.2.1 Maintenance Gland Packing This system uses "Flurograph 193" or equivalent packing, which is capable of providing excellent service under the harsh conditions. All these pumps utilize five rows of ¾ gland packing. The gland should be adjusted regularly to prevent excess leakage. The gland must not be over-tightened, as this will lead to overheating of the gland area and short life of the sealing components. The pumps will require repacking when the gland follower is tight against the stuffing box. It is imperative that all packing rings are replaced when repacking. Replacement of only the first few sets of packing will lead to premature wear of the shaft and other difficulties. Always replace the whole set. Each ring of packing should be inserted separately and pushed in place into the stuffing box. The split opening of the successive packing rings are to be positioned at 180° intervals. A slight leak is desirable from the newly packed gland to allow the packing time to bed in. Excessive tightening at this period will result in burning of the packing and scoring of the shaft. Gland packing removal The gland packing must be replaced when packing has deteriorated to a point that no further tightening of the gland will provide a seal or when the gland follower has reached the end of its travel. All packing rings must be replaced, adding one or two new rings on top of the old rings are not sufficient to provide a proper seal. 1. Remove the gland guard. 2. Remove the two gland adjustment nuts and withdraw the gland follower from the stuffing box. 3. Remove the two gland follower securing bolts then remove both halves of the follower from the shaft. 4. Using the appropriate packing removal tool remove all packing rings from stuffing box and clean out any remaining residue. Gland packing installation New packing rings must be installed one at a time by placing rings on the shaft and pressing each ring all the way into the stuffing box, ensuring the ends are fitted neatly together. Successive ring joints must be staggered around stuffing box. Pump models with lantern rings should have the lantern ring re-installed. Check with the pump manual for correct positioning between the gland packing rings. Fit gland follower to shaft and nip gland nuts up to pack gland packing. Ensure front face of gland follower has entered the stuffing box housing. If after tightening the gland nuts the packing has compressed enough to allow space for another ring, remove gland follower, fit extra packing ring, re-assemble follower and nip gland nuts up again. Back nuts off and leave finger tight until pump is started. Figure 8-1: Gland packing removal tool Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 68 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Maintenance Gland packing adjustment After pump has started, the glands must be adjusted to provide reasonable leakage. When water pressure is at a minimum the gland should leak slightly, therefore when this pressure rises, leakage will necessarily be excessive. If the gland is adjusted to provide optimum leakage at higher pump rpm (high pressure), insufficient leakage will occur when the rpm falls or is less from the point of adjustment. The gland sealing water should be as clean as possible, as large amounts of abrasive material can quickly wear the gland components. Always maintain a very small amount of water leakage along the shaft by regularly adjusting the gland. As well as lubricating and cooling the gland, the water escaping from the gland also prevents the ingress of air when the pressure at the shaft falls below atmospheric. If one of the following conditions applies, air may be induced into the pump through the gland. Packing has insufficient tension. Packing is excessively worn. Shaft sleeve is excessively worn. Standard procedure for gland adjustment: 1. Release gland nuts by one full turn. 2. Start the unit as per site procedures. Once unit has started, check for water moving past the gland and gland follower. A constant drip is ideal. This will reduce friction and prevent over heating of the gland. 3. If there is no flow of water past the gland or gland follower, stop the pump as per site procedures and isolate. 4. Once unit is isolated, loosen the gland nuts by one more turn. Repeat steps 2 through to 4 until a constant drip is achieved. 5. If the flow of water is too great past the gland follower, stop the pump and tighten the gland nuts by one turn at a time to ensure that only a constant drip is achieved. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 69 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.5.2.2 Maintenance Impeller The performance of the pump can change with excessive clearance between the impeller and the front wear plate/door. For best performance, it may be necessary to occasionally stop the pump and move the impeller forward. The procedure is: 1. Relax drive belts. 2. Loosen bearing housing clamp bolts. 3. In both metal and rubber lined pumps the impeller must just clear the front liner (throat bush). This is particularly important for high efficiency impellers without front vanes (type HE and HN). 4. Rotate shaft clockwise by hand and move bearing assembly forward (towards throat bush) by tightening the rear nut on the ADJUSTING SCREW until the impeller starts to rub on the throat bush. 5. Release the rear nut by one sixth of a turn, and then move bearing assembly back by means of front nut until housing touches the rear lug. Impeller adjustment is a key element in extending the wear life. Field tests on certain pumps indicate if impellers are adjusted right forward when fitted and again at regular intervals during the wear life, then an increase of 40–50% in life can be achieved over pumps which were not correctly adjusted forward at the initial fit-up. Further, pumps which were regularly adjusted over their life have shown a 20% increase over pumps which were only adjusted once at the initial fit up. Throat Bush Impeller Clearance between Impeller and Throat Bush Housing Clamp Bolts Adjusting Screw Figure 8-2: Impeller clearance Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 70 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Maintenance 8.5.3 Check Valve/Non-return Valve CAUTION When servicing and maintaining the non-return valve, the operator must check the pressure status of the discharge pipes. If the NRV flap is closed, pressure may be present and may cause release of pressure and liquid exposure to the operator. 8.5.4 Drive Belts NOTICE Refer to the “Drive Belt IOM” for instructions on v-belts. 8.5.5 Strainer Check and clean the suction strainer regularly. The required cleaning interval is dependent on the pH, SG, and viscosity of the fluid being pumped. CAUTION Follow safe operating procedures when servicing or maintaining the suction strainer. When cleaning the strainer, a drowning hazard is present and therefore the operator must undertake site specific procedures for servicing around water hazards. Use of appropriate harnesses, securing lines and life preservers may be required. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 71 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 8.6 Maintenance Maintenance and Service Guide NOTICE Check the pump twice a day (Every 10 hours) if it is operating. 8.6.1 Every 10 Operating Hours or Daily Table 8-1 lists the maintenance and service guide involved with the parts for a service every 10 operating hours or daily. Table 8-1: Maintenance and Service Guide for every 10 Operating Hours Schedule Maintenance Cassette Visually inspect assembly, paying attention to bolts, belts and couplings. Discharge assembly Check discharge pipe works for leaks. Repair if necessary. Gland packing Check gland leakage and adjust if required. Bare shaft pump lubrication system Visually check the grease level in the auto-greaser. Fill cartridges if required. Pontoon Check pontoon for unusual floatation and listing. 8.6.2 Every 250 Operating Hours (Perform in addition to Daily Schedule Items) Table 8-2 lists the maintenance and service guide involved with the parts for a service every 250 operating hours. Table 8-2: Maintenance and Service Guide for every 250 Operating Hours Schedule Maintenance Bare shaft pump Inspect the bare shaft pump glands. Check gland packing condition and repair/replace if necessary. Mounting bolts Inspect mounting bolts of the motor and bare shaft pump. Re-tension if required. Drive belts and pulley Inspect condition of belts and pulleys. Re-tension belts if required. Non-return/Check valve Check condition. Repair if necessary. Bare shaft pump lubrication system Check operation. Shutdown system Test all shutdown operations. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 72 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Maintenance 8.6.3 Every 500 Operating Hours (Perform in addition to 250 hrs Schedule Items) Table 8-3 lists the maintenance and service guide involved with the parts for a service every 500 operating hours. Table 8-3: Maintenance and Service Guide for every 500 Operating Hours Schedule Maintenance Bare shaft pump Impeller clearance to be adjusted when pumping slurry. Inspect the bare shaft pump gland seal, adjust if required, and repair/replace the packings if necessary. Refer section 8.7.2.1. Motor Service as prescribed in WEG electric motor manual. Drive belts and pulley Check belts for wear and tear, replace if necessary. Discharge valve Check all valves for operation, leaks, and damage. Gauges and measuring equipment Check operation and accuracy. 8.6.4 Every 1000 Operating Hours (Perform in addition to 500 Hours Service Items) Table 8-4 lists the maintenance and service guide involved with the parts for a service every 1000 Operating hours or daily. Table 8-4: Maintenance and Service Guide for every 1000 Operating Hours Schedule Maintenance Bare shaft pump Impeller clearance to be adjusted when pumping dirty water. Inspect the bare shaft pump condition. Make any adjustments required. Inspect the impeller, wear plate(s), and volute. Refer section 8.7.2.2. Non-return/Check valve Check condition. Replace valve if required. Bare shaft pump lubrication system Check operation. 8.6.5 Every 2000 Operating Hours (Perform in addition to 1000 Hours Service Items) Table 8-5 lists the maintenance and service guide involved with the parts for a service every 2000 operating hours or daily. Table 8-5: Maintenance and Service Guide for every 2000 Operating Hours Schedule Maintenance Bare shaft pump Inspect the bare shaft pump bearings for moisture inclusion. Inspect the bare shaft pump glands, adjust/replace if necessary. Change the bare shaft pump lubrication. Non-return/Check valve Check condition. Repair/replace valve if necessary. Pontoon Check pontoon for corrosion and damage. Repair and repaint corroded sections, repair damage as required. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 73 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 9 Lubrication Lubrication A correctly assembled and lubricated bearing assembly will have a long trouble free life, provided it is protected against ingress of water or other foreign matter and that it is adequately maintained. The bearing assembly should be opened at regular intervals (no longer than 12 months) to inspect the bearing. The 10/6 FFG bearing assembly is grease lubricated. Multiflo® recommends the use of Electro-Luber lubrication system to ensure the correct amount of grease is supplied to the bearings and labyrinths. Please refer to the information that follows for correct settings for the Electro-Luber greasing unit fitted to the 10/6 FFG pump unit. For bare shaft pump, lubricant will be delivered from the Electro-Luber greasers in pre-set quantities. Motor will be lubricated manually, refer WEG manual for quantities and intervals. The grease used for the components should be lithium complex soap thickener grease with EP additives and oxidant inhibitors. Refer “Electro-Luber automatic lubricators manual” in accompanying manual section for further information on pump bearing lubrication. 9.1 Safety DANGER Motor, bare shaft pump parts, ancillary equipment and all fluids may be at extremely high temperatures and pressures when the pump unit is stopped and may cause serious burns. Ensure pump unit has cooled down and energy sources have been isolated and dissipated before any checks or maintenance is carried out. WARNING Pump unit to be locked out, tagged out, and tested for dead before any maintenance or service is performed. CAUTION Wear personal protective equipment when operating, or servicing this unit. CAUTION If the pump unit is run without lubrication, the bearing can become very hot leading to burn injuries. Ensure that pre-start checklists are adhered to, to ensure the pump units lubricants are checked before operation. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 74 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 9.2 Lubrication Pump Unit Lubrication Schedule Table 9-1 lists the grade, quantity, and frequency of lubrication that needs to be undertaken for specific parts. Table 9-1: Grades and Frequency of Lubrication Grades and Frequency of Lubrication Item Recommended lubricant Bare shaft pump bearing Mobilgrease XHP 222 or assembly equivalent Frequency Maximum capacity Checked daily 2.6 litres ® GREASE GUIDE FOR 10/6 FFG BEARING ASSEMBLY IF GREASING MANUALLY Typical properties: Mobilgrease XHP 222 or equivalent Labyrinth Grease Port Drive End Bearing Lubrication Labyrinth Grease Port Impeller End Figure 9-1: Greasing guide for Warman 10/6 FFG bearing assembly if greasing manually Grease purging of the labyrinth maintains a barrier to contaminants entering the bearing assembly resulting in longer bearing life. The recommended intervals for labyrinth grease purging are as follows: Continuous Operation 16 hr day 8 hr day Pump End Labyrinth 4 shots/12 hours 4 shots daily 2 shots daily Drive End Labyrinth 4 shots/120 hours 4 shots weekly 2 shots weekly Bearings Drive and Pump End 3 shots daily 2 shots daily 1 shot daily NOTICE Shots calculated on standard manual grease gun delivery of 1 gram per shot. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 75 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 9.2.1.1 Lubrication Bare Shaft Pump - Greasing Unit The Electro-Luber is provided to grease the bare shaft pump labyrinths. Greasing of bearing is done manually. Jumbo Luber Mini Luber Figure 9-2: Auto-greaser - Electro-Luber For further information, refer to “Spare Parts Section" of this manual for more details on spare parts. The greasing unit will be filled with grease before shipping. The grease will dry out if left unprotected. Avoid direct sunlight. Do not mix different types of grease/oil. Incompatible lubricants may cause bearing damage. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 76 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 10 Troubleshooting Troubleshooting 10.1 Safety DANGER Pump unit should be isolated prior to any work on the electrical drive system being undertaken. WARNING Pump unit to be locked out, tagged out, and tested for dead before any maintenance or service is performed. WARNING Wear personal protective equipment when operating, or servicing this unit. CAUTION In the event of a malfunction or abnormal operation, shut off the pump unit immediately to prevent a dangerous situation and/or damage (possibly severe) to the pump or pump unit. Take the necessary precautionary measures in the case of hot, volatile, flammable and hazardous liquids. Leakage of environmentally harmful liquids can be extremely damaging to the environment. Do everything necessary to prevent this. Note: For liquids that congeal at temperatures lower than the operating temperature, close off the suction and discharge pipes and drain the pump as soon as the pump has been stopped. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 77 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Troubleshooting 10.2 Bare Shaft Pump Table 10-1: Troubleshooting Guide Symptoms Possible Causes Pump unit not starting Electric motor overload Pump unit starts but no delivery or delivers at a reduced rate. Remedies No power supply. Check for power to motor and external shutdowns, rectify. Pump seal too tight. Adjust seal (refer to bare shaft pump IOM manual in the accompanying manuals section for further information on seal). Pump bearing failure or seizure. Remove bare shaft pump and repair or replace bearings (refer to bare shaft pump IOM manual). Motor bearing failure or seizure. Remove electric motor and repair or replace bearings. Pump bogged. Check for any obstructions in any of the hoses connected to the pump unit. As a practice run clear water to rinse off mud from pump before shutoff. Speed too high. Check and run motor at recommended speed. Specific gravity and viscosity of pump fluid different from pump rating. Check application. Worn pump components. Identify and replace components. To avoid premature wear, follow maintenance as per manual. Low bare shaft pump rpm (550 RPM maximum for the pump unit). Check and run motor at recommended speed. Obstruction in hoses or pipes fitted to the unit. Check and clean obstructions. Pump located in a wrong position. Position pump at the appropriate location. Valves not working. Check condition and repair/replace if necessary. Foreign materials lodged in the impeller. Check and clean impeller. 10.3 V-belts Symptoms Possible Causes Remedies Small cracks on Vbelt side and base. Generally caused by shortage of belt tension but excessive heat and/or chemical fumes can also give same failure. Avoid belt contamination operation and storage. V-belt swelling softening. Caused by excessive contamination by oil, certain cutting fluids, or rubber solvent. Remove contamination replace belts. Usually caused by incorrect tensioning, principally on long centre drive. 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 a banded belt. or V-belt whipping during running. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 during Confirm correct belt tension and adjust. UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. source and Page 78 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Troubleshooting 10.4 Re-starting the Pump Unit after an Intervention In case the pump unit ceases to operate due to any of the above mentioned conditions or due to an emergency shutdown, the user must rectify the problem that caused the shutdown. After rectifying such problems, the pump unit can be restarted using the same procedures as explained in the section “Starting Procedures” of this manual. NOTICE Refer to section “Starting Procedures” of this manual. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 79 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 11 Dismantling and Disposal Dismantling and Disposal The approximate expected life of the pump unit is 10 - 15 years provided all maintenance procedures are followed as mentioned in this manual. After the end of life of the unit, the user must dismantle and dispose of the unit carefully, abiding the local law and regulations along with site conditions at the time of disposal. 11.1 Safety Notes – Dismantling and Disposal CAUTION It is the user’s responsibility to understand/identify all the inherent risks and consequences involved during dismantling/ disposal procedures and take necessary precautions against such risks. All disposal procedures MUST be carried out in accordance with the local laws and regulations at the time of disposal. Only site approved procedures and Environmental, Health and Safety (EHS) risk assessment MUST be used. Liquid MUST be correctly identified and MUST be disposed of in accordance with local laws and regulations at the time of disposal. Only site approved procedures and Environmental, Health and Safety (EHS) risk assessment MUST be used. Use only designated lifting points for lifting operations. Mass of the components must be taken into consideration while selecting appropriate lifting equipment. The user must identify appropriate tools/equipment required to perform the dismantling procedures. After dismantling the components, ensure that proper storage measures are undertaken. Ensure that there is at least six (6) meters free space around the unit before performing any disassembly procedures. It is the user’s responsibility to provide the necessary training required to perform any dismantling and disposal procedures on the pump unit. CAUTION Only approved recyclers/vendors to be used for disposal of components. Materials like electrical wires must be dealt with extreme caution and the user MUST understand the risks during disposing flammable material. All procedures to be carried out by skilled personnel only. WARNING Wear personal protective equipment when operating, or servicing this unit. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 80 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Dismantling and Disposal 11.2 Decommissioning and Dismantling 11.2.1 Pump Base Dismantling Switch “OFF” all power supplies. Disconnect any power source to the unit. Ensure that there is no power supply to the unit or any individual components. Drain the pump of any liquid. Separate cassette and pontoon by lifting the pump cassette from the pontoon. Disassemble the suction assembly components. Disassemble the discharge components. Disassemble the pump cassette components. Remove the bare shaft pump and the bare shaft pump components. Remove the belts guards. Remove the motor and dismantle all electrical wiring. Remove all additional accessories and any additional components. Once all items are dismantled, sort out the components according to the material and the nature of disposal. For example, all steel components to be recycled can be gathered together and stored in appropriate containers. All non - metallic components can be gathered together for recycling. E.g. Hydraulic hose, shrink wrap from wiring, etc. After dismantling all the components, pack them in appropriate storage containers and now they can be sent off for recycling. Refer to the motor manual supplied on further information on dismantling the motor. For any queries on how to dismantle any components, please contact Multiflo® customer services. All dismantling procedures must be undertaken after analysing all risks. The user must keep ready all safety and lifting equipment required for dismantling procedures. The user must not try to dismantle the unit without fully understanding the procedures and training required for such procedures. If any individual component is still in a working condition then the user can decide what to do with such a component. it is recommended that such individual components should be used only after understanding the intended operation, usage, range of application and necessary conditions pertaining to the component. CAUTION The operator must confirm hazards associated with the liquid that was last pumped when undertaking servicing or dismantling. Incorrect identification of hazardous pumping fluids may result in exposure to potentially hazardous materials. When recycling pump components, they must be decontaminated before handling of maintenance staff to eliminate the exposure to hazardous materials. When disposing of components, they must be decontaminated before handling of maintenance staff and distributed into waste centres. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 81 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Dismantling and Disposal 11.2.2 Dismantling the Pontoon (with the centreframe removed from the pontoon) Remove the handrails and kickplates from the pontoon. Remove any removable mesh. Remove the tow chains. Using appropriate lifting equipment, remove the left hand side float from the assembly. Using appropriate lifting equipment, remove the right hand side float from the assembly. 11.3 Disposal 11.3.1 General Disposal Proper disposal of the pump unit components becomes crucial after dismantling. All materials set aside for disposal must be disposed of according to laws set forth by the local authorities at the time of disposal. Proper disposal becomes obligatory as toxic wastes can cause ill effect on the environment and life systems. For example, toxic wastes can seep into the ground contaminating water supplies and may cause diseases. Toxic waste causes pollution and has a negative impact on the ecosystem. It is the user’s responsibility to fully understand the laws and regulations set forth by the local authorities at the time of disposal. Waste management methods might vary specific to different geographies and territories and the user MUST understand these regulations. Domestic waste collection services are often provided by local government authorities, or by private companies in the industry. The user must find out a list of approved vendors/recyclers and the components must be sent only to such agents for disposal/recycling. Protective equipment such as gloves and goggles should be used while handling chemical of toxic nature. It is preferred that at least two persons should be present at all time while working with chemicals. Waste products and disposals must be discharged with proper neutralization. If the material to be disposed is extremely toxic or poisonous, the material should be kept in closed container and sent to appropriate agency for proper disposal. All materials must be sent to approved recyclers, Any waste oil present must be collected in approved seal containers and must be disposed via approved waste management companies. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 82 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12 Appendix Appendix The appendix presents further reference material on the pump set. 12.1 Certifications 12.1.1 OHSAS 18001:2007 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 83 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.1.2 AS/NZS 4801:2001 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 84 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.1.3 AS/NZS ISO 14001:2004 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 85 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.1.4 AS/NZS ISO 9001:2008 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 86 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.2 General Sales Condition Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 87 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 88 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 89 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Appendix Page 90 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.3 Spare Parts List Appendix To order spare parts or general guidance/queries on the products/spare parts contact Multiflo® Spare Parts and Customer Support on: Telephone: +61 (0)7 5449 3032 Facsimile: +61 (0)7 5351 1703 Email: [email protected] Head Office & General Switchboard: +61 (0)7 5449 3000 Customer Support Hours: Monday to Friday 7:00 am – 4:00 pm Note: Always quote model and serial number of pump when ordering spare parts. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 91 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.3.1.1 Major Components - Pontoon Assembly Appendix 2 3 1 4 5 6 NO. DESCRIPTION 1 Belt Guard Assembly 2 Electric Motor 3 Handrail Assembly 4 Pontoon Stair Arrangement 5 Ladder Tray Assembly 6 Pontoon LH Float Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 92 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.3.1.2 Major Components - Pontoon Assembly (continued) 2 Appendix 3 1 4 7 6 5 3 NO. DESCRIPTION 1 Centreframe Mesh 2 Pump Cassette Frame 3 Customer Supplied Connection Box 4 Life Ring 5 Pontoon RH Float Assembly 6 Discharge Assembly 7 Pontoon Centreframe Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 93 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.3.2 Major Components - Cassette Assembly Appendix 2 1 3 4 5 6 7 NO. DESCRIPTION 1 Electric Motor 2 Belt Guard Assembly 3 Motor Mount Plate 4 Electro-Luber Assembly 5 Bare Shaft Pump 6 Pump Cassette Assembly 7 Suction Strainer Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 94 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.4 Pump Cassette Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 8 3 4 7 6 5 NO. DESCRIPTION PART NUMBER QTY 1 Electric Motor MF261724 1 2 Motor Mount Plate MF262157 1 3 Guard Mount MF261831 2 4 Cassette Frame MF261626 1 5 Bare Shaft Pump MF260392 1 6 Strainer MF261813 1 7 PFC MF261634 1 8 Jacking Bolt Assembly MF102043 4 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 95 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.4.1 Drive Belts and Guards Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 3 2 5 4 6 NO. DESCRIPTION PART NUMBER QTY 1 Pulley MF11B000548 1 2 Taperlock MF11B000216 1 3 Pulley MF11B000551 1 4 Taperlock MF11B000218 1 5 Belt Guard Assembly MF260819 1 6 Belt MF261734 5 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 96 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.4.2 Discharge Assembly Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 2 1 5 7 6 3 4 7 3 NO. DESCRIPTION PART NUMBER QTY 1 Discharge Pipe Spool MF261664 1 2 Valve MF03B012271 1 3 Elbow MFNRV150-23 2 4 Valve MF03B009464 1 5 Nipple MFNRV150-21 1 6 Gasket MF04B001541 2 7 Discharge Pipe Support Clamp MF261854 2 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 97 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.4.2.1 Discharge Assembly (continued) Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 3 4 5 2 1 7 6 NO. DESCRIPTION PART NUMBER QTY 1 Spool MF261658 1 2 Valve MF03B12864 2 3 Valve Air Release MF239998 1 4 Gasket MF04B001536 1 5 Discharge Pipe Spool MF261635 1 6 Discharge Pipe Support Clamp MF261854 1 7 Gasket MF04B001541 2 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 98 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.5 Handrails – Pontoon LH Float Assembly Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 3 2 1 4 5 6 7 NO. DESCRIPTION PART NUMBER QTY 1 Handrail MF261576 1 2 Pontoon Gate Assembly-LH Float MF260488 1 3 Handrail MF261575 1 4 Kickplate MF261569 1 5 Pontoon Stair Assembly MF259998 1 6 LH Float MF261566 1 7 Kickplate MF261570 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 99 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.5.1 Handrails – Pontoon RH Float Assembly Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 8, 9 10 3 11 2 1 4 5 6 7 NO. DESCRIPTION PART NUMBER QTY 1 Handrail MF261576 1 2 Pontoon Gate Assembly-RH Float MF260488 1 3 Handrail MF261579 1 4 Kickplate MF261582 1 5 Pontoon Stair Assembly MF259998 1 6 RH Float MF261588 1 7 Kickplate MF261570 1 8 Screw MF01B000968 72 9 Washer MF01B002005 72 10 Access Cover MF230805 6 11 Gasket MF230806 6 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 100 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.5.2 Centreframe – Pontoon Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 3 5 4 NO. DESCRIPTION PART NUMBER QTY 1 Well Cover Panel Mesh MF261880 1 2 Well Cover Panel Mesh MF261902 1 3 Centreframe MF26159 1 4 Well Cover Panel Mesh MF261901 1 5 Kickplate MF260829 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 101 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.5.3 Centreframe – Pontoon (continued) Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 3 8 4 1 5 8 7 6 NO. DESCRIPTION PART NUMBER QTY 1 Handrail MF260827 2 2 Handrail MF261908 2 3 Kickplate MF261921 1 4 Handrail MF261907 2 5 Well Cover Panel Mesh MF261904 1 6 Kickplate MF260829 1 7 Kickplate MF261871 1 8 Kickplate MF261870 2 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 102 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6 Bare Shaft Pump Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 2 1 3 4 NO. DESCRIPTION PART NUMBER QTY 1 Bare Shaft Pump MF260392 1 2 Discharge Joint Ring F6132S01 1 3 Discharge Flange MF212180E05 1 4 Suction Joint Ring FG10132S01 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 103 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.1 Bare Shaft Pump (continued) Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 3 4 7 5 6 NO. DESCRIPTION PART NUMBER QTY 1 Gland Guard Upper MFMSA420N002 1 2 Housing Clamp (c/w 1 Nut) F012ME62 4 3 Adjusting Screw (c/w 3 Nuts and 2 Washers) F001ME62 1 4 Base F003MD21 1 5 Washer F011E63 4 6 Adaptor Plate Stud c/w 2 Nuts FH039ME63 3 7 Gland Guard Bottom MFMSA420N001 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 104 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.2 Bearing Assembly – Wet End Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 6 5 4 2 3 1 7 8 9 NO. DESCRIPTION PART NUMBER QTY 1 Labyrinth FF062-10E62 1 2 Bearing Seal FF089-10S10 1 3 Set Screw MFBLTMSS12035 8 4 Gasket FF025S14 1 5 Bearing S009 1 6 Bearing Housing FF004D21 1 7 Shaft FFG073ME05 1 8 Piston Ring YE108G02 2 9 Bearing Cap FF024-10 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 105 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.2.1 Bearing Assembly – Drive End Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 4 5 3 1 2 7 6 8 NO. DESCRIPTION PART NUMBER QTY 1 Labyrinth Socket Set Screw (Cup Point) M12A2-25H 2 2 Set Screw MFBLTMSS12035 8 3 Piston Ring YE108G02 2 4 Gasket FF025S14 1 5 Bearing S009D 2 6 Bearing Cap FF024-10 1 7 Bearing Seal FF089-10S10 1 8 Labyrinth FF062D-10 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 106 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.3 Gland and Packing Kit Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 5 2 4 3 2 1 2 2 6 7 8 9 NO. DESCRIPTION PART NUMBER QTY 1 Gland F044C23 1 2 O-ring F109S10 4 3 Shaft Sleeve-Short FG117C21 1 4 Shaft Sleeve-Long F075C21 1 5 Spacer FG179C11 1 6 Nut MF390-34N 2 7 Bolt F045MC23 2 8 Packing Kit MFPAK-DWF193 1 9 Neck Ring MK586070C23 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 107 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.4 Wet End Parts Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 5 2 4 3 1 NO. DESCRIPTION PART NUMBER QTY 1 Clamp Bolt c/w 1 Nut 1 Washer MF106031 16 2 Front Door MFMK584485H7A 1 3 Bowl Seal FX6124S00 1 4 Impeller FX6145HETIC26 1 5 Volute MF212190H7A 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 108 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.5 Wet End Parts (continued) Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 3 4 5 6 7 NO. DESCRIPTION PART NUMBER QTY 1 Back Liner MF212187H7A 1 2 Stuffing Box O-ring FH122S01 1 3 Stuffing Box MF212188H7A 1 4 Bowl Seal FX6124S00 1 5 Adaptor Plate MF212189D21 1 6 Clamp Bolt c/w 1 Nut 1 Washer MF106031 16 7 Back Liner Stud c/w 1 Nyloc Nut FX026ME62 4 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 109 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.6 Bearing Housing Assembly Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 1 NO. DESCRIPTION PART NUMBER QTY 1 Plug WP4P1-E 4 2 Shaft Key S070E05 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 110 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.7 Ladder Tray Assembly Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 7 6 2 5 4 3 NO. DESCRIPTION PART NUMBER QTY 1 Cover MF05B000093 2 2 Cover MF05B000539 2 3 Cable Ladder MF05B000123 1 4 Divider Strip MF05B000049 2 5 Cable Ladder MF261616 1 6 Clamp MF05B000045 16 7 Cable Ladder MF05B000240 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 111 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.8 Life Ring Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 1 2 3 NO. DESCRIPTION PART NUMBER QTY 1 Life Ring MF102233 4 2 Pipe Strap MF01B003245 4 3 Life Ring Mount MF211378 4 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 112 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.6.9 Electro – Luber Mount Appendix NOTICE Always quote model and serial number of pump when ordering spare parts. 2 1 3 4 5 6 12 7 11 10 9 8 NO. DESCRIPTION PART NUMBER QTY 1 Jumbo-Luber MFELBRB500 1 2 Mini-Luber MFELBRB125 3 3 Bush MF03B002724 3 4 Adaptor MF03B005316 4 5 Hose Assembly MF262618 1 6 Hose Assembly MF262185 1 7 Hose Assembly MF262182 1 8 Hose Assembly MF262180 1 9 Bolt MF01B001773 2 10 Nut MF01B002144 2 11 Bush MF2024922 2 12 Electro-Luber Mount MF262165 1 Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 113 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.7 Checklists Appendix The following checklists and procedures should be printed and taken into the field for appropriate use. 12.7.1 Field Observation Checklist PUMP No. PUMP UNIT SERIAL No. SAFETY Only undertake observational checks while the pump is in operation. Any physical checks of the pump will need to be undertaken while the pump is offline. Use approved personal protective equipment at all times. If there is a defect identified, safely shutdown the pump following the appropriate shutdown procedure. Follow up any defects with relevant service personnel. CHECKLIST O.K. 1 Noise 2 Gland packing 3 Corrosion 4 Bearings 5 Gauges 6 Drive belts 7 General inspection of remainder 8 Electrics/Wiring 9 Non-return valve\Check valve 10 Strainer depth DEFECT ACTION TAKEN COMMENTS: NAME (Print): SIGNATURE: DATE: Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 114 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.8 Tightening Torque Values Appendix 12.8.1 Metric Hex Bolts & Screw Metric Hexagon Bolts & Screws, Coarse Pitch Threads Property Classes 4.6 & 8.8 Property Class 4.6 Nominal Diameter Pitch Property Class 8.8 Induced Bolt Tension corresponding to 65% Torque (Nm) of Proof Load (kN) Tension 65% Induced Bolt Tension corresponding Torque to 65% of (Nm) Proof Load (kN) Across Flats Wrench Size M6 1.00 2.94 3.5 7.54 9.0 10.00 M8 1.25 5.36 8.5 13.80 22.0 13.00 M10 1.50 8.45 17.0 21.90 44.0 16.00 M12 1.75 12.40 30.0 31.80 77.0 18.00 M16 2.00 22.90 73.0 59.20 190.0 27.00 M20 2.50 35.80 143.0 95.60 372.0 32.00 M24 3.00 51.60 248.0 138.00 640.0 41.00 M30 3.50 81.90 491.0 219.00 1314.0 46.00 M36 4.00 120.00 864.0 319.00 2297.0 55.00 Note: All Torque values are in Nm. Multiply by 0.738 for lbf.ft. Note: For Hot-Dip Galvanised product (plus no lubrication) a friction factor of 2.1 may be applied (eg: for Hot-Dip Gal M12 Class 8.8, final torque required will be 77 x 2.1 Nm = 161.7 Nm, etc). Note: If lubrication is applied, please consult your manufacturer/supplier for friction factors to apply. Bremick Pty. Ltd. Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 115 Issue Date: 13 October 2017 MEP-420HV 10/6 FFG PONTOON UNIT 12.9 List of Accompanying Manuals Appendix The following items are accompanying manuals that are provided along with this manual: - P03 AH Slurry Pumps M9 Gland Sealing BA2 Basic Bearing Assembly MF-420HV FFG BSP IOM 12.10 Reference Documents - Electro-Luber Lubricators IOM WEG electric motor manual Drive Belt IOM Revision: Version 1.0 Serial number: MEFP-420HV-195-08.28 UNCONTROLLED DOCUMENT Copyright © 2017, Weir Minerals Australia Ltd. All rights reserved. Page 116 Issue Date: 13 October 2017
