Price Pumps Installation and Operation...

Price Pumps Australia Phone: +61 7 49985070 Mob 0409 827 290 [email protected] www.pricepumpsaustralia.com.au of 21

Operation Manual Model: PPAMAH, PPAMH, PPAMHH, PPAMG, PPAMGH, PPAML,

PPAMM, PPAMZGB, PPAMD, PPAMZJ, PPAMSP, PPAMAF SLURRY PUMP

ABN 17 154 031 802

21 Ginger St, Paget Mackay Qld Australia 4740

PO Box 5709, Mackay Mail Centre Qld Australia 4741

Ph: +61 07 4998 5070 Fax: +61 07 4952 1944

Mobile: +61 0409 827 290

Email: [email protected]

Heavy Duty Pumps For Mining and Industry

Price Pumps Australia Phone: +61 7 49985070 Mob +61 0409 827 290 [email protected] www.pricepumpsaustralia.com.au

CONTENTS

1. Safety Precautions 3

2. General Introduction 3

3. Construction 4

4. Notes Regarding Assembly 9

5. Operation 15

6. Maintenance 17

7. Troubleshooting 20



1. Safety Precautions

The following safety information relating to pump operation should be adhered to at all times. Failure to do so may result in injury to personnel, and damage to equipment.

Do not apply heat to the impeller hub or inlet eye to assist impeller removal. Application of heat may result in shattering of the impeller, resulting in injury or equipment damage.

Where auxiliary equipment is associated with a pump (e.g motors, drive belts, drive couplings, speed reducers, variable speed drives, etc.), all relevant instruction manuals should be consulted and recommended procedures implemented during installation, operation and maintenance of the pump system.

Do not operate the pump for an extended period with low or zero flow rate. Failure to observe this warning could result in the pump overheating, and vaporisation of the pumped fluid, with generation of very high pressures. Serious injury to personnel or damage to equipment may result from such action.

Check drive motor rotation prior to fitting of drive belts or couplings. Incorrect motor rotation may cause personnel injury or equipment damage.

Do not feed very hot or very cold fluid into a pump at ambient temperature. Thermal shock may result in fracture of pump wet-end parts.

When the pump is in operation, hands should not get into or remove the protective shield of the pump. This may result in serious injury to personnel.

2. General Introduction

Pump models PPAMAH, PPAMH, PPAMHH, PPAMD, PPAMG, PPAMGH, PPAML, PPAMM, PPAMZGB, PPAMZJ are horizontal slurry pumps. Models PPAMSP and PPAMAF are vertical slurry pumps, they are centrifugal pumps. They have been designed for the handling of high abrasive or corrosive, high density slurries. These are widely used in Metallurgical Coal Mining, Petroleum & Chemical Transportation, River & Channel Dredging, Building Material and Municipal projects. Its construction can be divided into the following types based on the application ranges

a) Models – PPAMAH, PPAMH, PPAMHH, PPAMD, PPAMG, PPAMGH, PPAMM, PPAMZGB, PPAMZJ, PPAMAF pumps are also called heavy duty pumps. They can be operated in multi-stage series installation within the maximum working pressure of various types of pump because these pumps are fitted with thicker wear parts and large duty frame, suitable transporting highly abrasive, high density slurry or low density high head slurry. Among them, type NSS pump is suitable for lower density and abrasive high head slurry. The above types of pump also can be used in certain corrosive slurries.

b) Model PPAML pump is a light duty slurry pump. Compared with heavy duty slurry pumps, this pump is high speed, small, light-weight and suitable for transporting fine particle lower density slurry (the maximum concentration weight does not exceed 30%). It can be used for transporting high density lower abrasive slurry as well.

c) Model PPAMD dredge pump and PPAMG gravel pump are designed for high density and lower abrasive slurry, which are suitable for delivering gravel, mud and slurry containing larger solids. These pumps are not for corrosive slurry.



d) The wet parts of PPAMAHR, PPAMLR, PPAMMR pumps should be elastomer. Its casing, cover and driver can be exchanged with PPAAHL types of pump are for the fine particle and corrosive slurry.

3. Construction

The construction diagram of Models NZS, NS, NSS, NN see Fig.1;

The construction diagram of Models NZSI, NNI, NOI see Fig.2;

The construction diagram of Model NO see Fig.3;

The construction diagram of Model NT see Fig.4;

The construction diagram of Model NHN see Fig.5;

The construction diagram of Model NZU see Fig.6.

The construction for all horizontal slurry pumps is similar, except for the pump head (include pump body, cover, impeller and etc.). All of them adopt the same series of driving. Its construction will be described according to the following items of pump head shaft seal and driving assembly required.

a) Pump Head

Type NO, NN, NZS, NS, NSS, NATY, NW, NAQ pumps are designed with double volute that pump body and cover has been fitted with metal or runner liner (including impeller, liner insert, insert plate). A cast iron or S.G. iron pump body and cover depending on the working pressure, casing split on the vertical centreline serves to support and be connected by means of bolts. Pump body is bolted and spigotted to the frame and discharge branch may occupy any one of eight positions. Side sealing vanes on both sides of shoulder may relieve the leakage and raise the life and efficiency of the pump. Type NZSI, NOI & NNI pumps are double volutes too. Its casing and cover is fitted with the interchangeable rubber liner (including impeller, front & back liner). Pump casing and cover can be exchanged with that of type NZS, NO & NN pumps. It’s driving and installation is correspondence to type NZS, NO & NN pumps. Type NT pumps are the construction of single volute (without liner). Pump body cover and impeller is made of resistance abrasion alloy. Pump body and cover are connected by the clamping construction. For ease of assembly and disassembly, the discharge branch may be rotated in any direction. Inlet for all types of pump is horizontal direction and pump should rotate clockwise in view of driving direction. Type NHN is single volute. Type NZU is double volutes.



Fig. 1 – NZS, NN, NS, NSS, NATY, NW, NAQ pump construction

Fig.2 – NZSI, NNI, NOI pump construction

Fig.3 – NO pump construction



Fig. 4 – NT pump construction

b) Shaft Sealing Assembly For horizontal slurry pump there are two kinds of shaft seal – expeller type shaft sealing and gland packing assembly.

i. Expeller Type Shaft Sealing Assembly For the single stage pump and first stage pump of the multi-stage series the expeller type shaft sealing assembly is normally fitted when the positive pressure of inlet is larger than 10% than that of the outlet. Expeller type sealing assembly has the advantages of not requiring flushing water, no diluting pulp, good sealing result and so on.

ii. Gland Packing Seal The gland packing seal is single and easy to maintain, but must require the flushing water service. For the duties where it is not suitable for expeller seal the packed gland should be used. c) Driving Assembly All types of slurry pump may be adopted with the same series of driving assembly, including frames and bearing assemblies. An extremely rigid shaft of a larger diameter with short overhang to impeller eliminates deflection and vibration under all condition of use. Large, wide, heavy duty, grease lubricated single or double row taper roller bearings and roller bearings are fitted based on the transmitting power. The bearings are more than ample to carry all radial and thrust loads at maximum pump duty and have an unusually long life factor. Spigotted end covers close the housing and carry labyrinth sleeve and ring (bearing seal) to prevent slurry and dirt entering the bearings. The sump pump model NHN is a vertical, centrifugal slurry pump. The pump casing, impeller and wear plate are made of wear resistant material. The sump pump has a simple construction and can be easily installed. The pump casing is fixed to the



frame with bolts and the bearing body is installed on the top end of the frame. The double row taper roller bearings near pump and the single row cylindrical roller bearing near drive end may bear the max axial load of the pump. The base plate or frame of motor is installed on the bearing body. They may be directly driven or by vee belt. The belt pulley may be easily replaced for adjusting the pump speed to meet the duty variation or performance variation after the pump has been worn. There is split mounting plates on the frame. The mounting plates may be easily mounted on the steel frame base or concrete base. It has advantages of easy installation and convenient operation. The pump can be immersed in slurry sump for work. The inlet of pump is equipped with lower strainer so as to prevent the larger particles from entering the pump. The construction of the model NHNI is the same as model NHN, but for NHNI the outside of parts immersed in the slurry is lined with corrosive resistant rubber. These parts with rubber liners are pump casing, impeller and wear parts. The connecting bolts immersed in the liquid are all lined with rubber protecting bush. The driving end of type PPR pump is as same NHN pump.

Fig. 5 – Constructional drawing for type NHNI sump pump

Series NZU froth pump has the advantage of simple construction, high degree of generalise and easy installation and application. For the construction diagram see Fig.6.

i. Driving part: The driving part of ZU series pump is interchangeable with that of SP or SPR series pumps. Bearing body has been fixed with motor base or bracket so that it can be connected by direct driving or intermediate driving. It is easy to replace the pulley to change the speed of pump as required.

ii. Slurry tank: The slurry tank is made of structural steel. The tank is fitted with

tangential inlet and overflow tank. Overflow tank can easily return overflow to the slurry pool. The slurry can be rapidly entered into pump through tangential inlet and a part of foam can be removed.

iii. Pump head: The construction of the pump head is double volute and identical with ZS series slurry pumps of same diameter. From the difference of



transported medium, the materials of wet part will be metal, rubber and other non-ferrous materials. For the material of metal, its casing, cover, volute, and front liner plate can be interchanged with ZS series slurry pumps of the same diameter. For the material of rubber or other non-ferrous material, the front and back liner can be interchanged with ZSI series pump of the same diameter.

1. Casing

2. Cover

3. Front liner plate

4. Volute

5. Impeller

6. Liner plate

7. Slurry tank

8. Shaft

9. Bearing body

10. Bearing

11. Labyrinth ring

12. Shaft sleeve

13. Bearing

14. End Cover

15. Oil slinger

4. Notes Regarding Assembly

a) Bearing Assembly It is advisable to preheat the bearing inner ring or cones (never exceed 120°C). With shaft in the vertical position the heated inner ring or cones can be slipped on and pressed or tapped up to shoulder or grease retainer. For the double rows of taper roller bearings, its inner ring or cones, cup and spacer may be not interchanged with similar assembles of the same type bearings. For type – A, B, C, D, E bearing assemblies, the single row taper roller bearing should be adopted. During assembly, axial gap in the end cover should be adjusted by means of shims. The value of axial gap should be corresponding with the following table.

Frame A B C D E F

End Play (mm) 0.05-0.15 0.1-0.2

0.15-0.25 0.18-0.28 0.4-0.5 0.5-0.6

For type – R, S, ST, T, TU, V bearing assembly, double rows taper roller bearings are fitted on the pump end. The axial gap may not be required to adjust because the end pay may be guaranteed by them. Apply oil or light grease to bearing lands. The seal in



the end cover of bearing is used of labyrinth and piston ring. Position piston ring gaps diametrically opposite. It is recommended that lubricating grease used in roller bearings should be No. 2 or 3, SY1412-75 Lithium Based grease. The recommended initial quantity of grease to be used for each bearing is as following tale during assembly. (in unit of gram)

B C D E F R.RS S.ST T.TU Drive End 30 50 100 250 500 200 500 1150 Wet End 30 50 100 200 500 400 1000 2300

Fig. 7 –

b) Gland Assembly for horizontal pump Gland assembly should be consisted of stuffing box, shaft sleeve, shaft spacer, shaft sleeve O-ring, neck and lantern rings, packing glad and cover. Two types of lantern ring can be seen in Fig. 9 and 10. For the application of suction head the installation form show Fig. 9 can be selected and the installation form shown in Fig. 10 for the application of positive suction head. The O-ring between the shaft sleeve and spacer must be positioned correctly. Packing Selection: Asbestos packing with PTFE should be often selected when the working pressure is lower than 1 MPa. When the pressure is higher than 1MPa or pumping corrosive slurry, synthetic aramid fibre with PTFE should be used.



c) Centrifugal Seal Assembly for horizontal pump (see in Fig.11 & 12) Centrifugal seal assembly is included with expeller rind, expeller, shaft sleeve, spacer and so on. For the rubber expeller ring, the lip-sealing ring and cover should be used. Packing neck lantern ring and packing gland should be used for the metal expeller ring. All shaft sealing assemblies are liner-changeable. Which one can be selected depends on the user’s application. Note: All the sealer rings must be positioned correctly.



d) Pump Head Assembly for Horizontal Pump Fit the seal ring into the frame plate groove. To hold frame plate liner insert temporarily in its correct position, move bearing assembly back by means of locating nut (*303) and then fit the impeller and volute liner. Then put the volute liner against frame plate. At last, fit cover plate insert into the cover plate for means of tightening the studs. Then, assemble cover plate with frame plate. During assembly the rubber lubricant on the fitting surface, it is a must to ensure that the seals be positioned correctly in assembly. In order to guarantee the relative position of all fitting parts correct each other. The



lifting tube (*302) and locating nut (*303) for frame plate and frame plate liner, volute lifting beam (*304) and so on tools can be used (see Fig.13).

e) For type – R, S, ST, T, TH and U heavy-duty bearing assemblies with release

collar, its three socket head cap screws firstly unscrew, then screw them into three other tread holes, in this way protrude three pieces of collar, then loosen the impeller during disassembly.

f) Notes when assembly for vertical pump

1. Assembly of bearing assemblies When assembling, the bearing assemblies must be preheated and the temperature must not be more the 120°C. Double rows, tapered, roller bearing are adopted for the lower bearing and their cone, cup and position sleeve is assembled in set, which cannot be interchangeable with corresponding parts of the same kind of bearings. When the lower end cover of bearing is assembled, it must be noted that the surface of lip seal in recess of lower end cover should be outward and the oil retainer, etc. must agree to the position in assembly drawing. When piston ring is assembled, it must be noted that the mouth of the piston ring should not be overlapped at the direction of diameter. Because axial clearance has been ensured by bearings themselves, the clearance of the bearing assembly of the sump pump should not be adjusted in the assembly. But after assembly, it is suggested that the end face clearance in installation should be checked according to the values in the following table.

Bearing assembly End face clearance (mm) PV 0.074-0.160



QV 0.114-0.208 RV 0.084-0.211 SV 0.064-0.206

TV 0.127-0.259

2. Installation of support, mounting plated and pump casing for NHN pump The bearing assembly and support is connected by bolts. The split mounting plates are assembles around the circle of support and fixed on support with studs. Then back liner, impeller and pump casing is assembled. When assembling it must be noted that the relative position among bearing body, support, mounting plates and pump casing must be corresponding to the following figure to ensure the relative position of discharge pipe and oil nozzle. See figure 14.

The connection bolts between support and pump casing must be smoothly locked. Check whether the impeller rotates stably (if there is friction, put an insert at connecting bots between bearing body and support to adjust it.). At last the upper & lower strainer and discharge is installed, the upper part of discharge is fixed on the mounting plate by screws.

3. Installation of bearing assembly, tank and pump head for NZU pump Bearing assembly will be put on the top of tank and fixed by bolt. Then install the sealing gasket of tank. Pump casing will be fixed on the tank by means of stud. Next install liner plate, impeller, volute, pump cover and soon in sequence according to diagram. Pump cover should be fixed with pump casing by stud. The connecting stud of pump casing to tank should be tightened evenly. Check the impeller whether it rotates evenly or not. If any friction it can be adjusted by the use of shim in the stud on the top of tank and bearing body. At last all fasteners should be tightened. 5. Operation



a) Starting Before starting the following steps must be taken.

i. Efficient service of pump can be obtained only by installing the pump on adequate foundations which should be designed to take all loads from the pump and motor and to absorb any vibration. All hold-down bolts should be fully tightened.

ii. Pipelines and valves should be supported independently of the pump. Appropriate joint must be used at the pump flanges. In some pumps, the metal liner projects a short distance past the flange. Car should be taken in such instance not to over tighten the flange bolts so as to not damage the joint ring.

iii. Before use of pump, the shaft should then be rotated by hand (clockwise) to ensure that the impeller turns freely within the pump. At any sign of scraping noise from the pump, the impeller clearance must be adjusted.

iv. Start motor, check rotation and correct it if necessary to produce pump shaft rotation, indicated by arrow on the pump casting. Rotation in the direction opposite to the arrow on the pump will unscrew the impeller from the shaft causing serious damage to the pump.

v. For direct coupled, the pump and motor shaft should be accurately aligned. If V-belt driven, the pump shaft must be parallel with the motor shaft. The position of pulley should be adjusted in order to make it perpendicular to belt and to prevent them from excessive wear and vibration. The adjustment pulley should meet the requirements of a1=a2 in Fig.16, when SPA and SPB are matched with SPA SPB and SPB SPC respectively.

vi. A removable piece of pipe should be used on the intake side of the pump. The pipe should be sufficient length to allow removal of pump cover plate and to enable access to pump wearing parts. Its length should be seen in outline diagram of each pump.

vii. Shaft Seal Check

For centrifugally sealed pumps fitting grease cup in the expeller ring, screw the grease cup down a few turns to charge the static seal chamber with grease due to difference sealing construction at stopping. It is recommended that sodium calcium based soap grease be used. (SYB1403-62) For gland sealed pumps, check gland water is available and that it is sufficient quantity and at the correct pressure. Screw glad nut to adjust the tightness of packing rings and quantity of cooling liquid. Always maintain a small amount of clean water leakage along the shaft by regular adjusting the gland. If packing rings are too tight, the shaft sleeve shows signs of heating and sacrifice power. If the packing rings are too loose, the leakage would be excessive. It is normal for the pressure of sealing liquid to be 3.510-



2MPa higher than that of pump outlet. It is recommended that the quantity of sealing liquid should be supplied by following the below table.

We only

introduce our recommendation adjustment method as follows for reference.

(1) Firstly calculate pretension Q

� =��(�.��)�∙�

�∙�∙�+�� (Newton)

(2) e value can be looked up from the curve based on pretension and vee-belt type.

(3) Through formula � = �.��

��

F is found.

(4) R value related with the type of Vee-belt can be looked up in Fig.15. According to the method in Fig.15 and the centreline distance adjusting between two pulleys, the required pretension will be reached.

Where Q – minimum pretension suspended distance of each Vee-belt at static (Newton)

f – Total pressed amount in suspended distance.

� – Angle coefficient (0.9 approx.)

� – Working coefficient (1.4 approx.)

L’ – Centreline distance of pulleys

P – Motor rated power (kw)

Z – Piece number of Vee-belt

V – Line velocity (m/s)

m – Centrifugal force coefficient (see in Table 1)

e – Pressed amount e (mm) in 100mm length of suspended distance (seen in Fig.15)

Table 1.

Type SPA SPB SPC SPZ

R 60 90 120 30

m 0.12 0.20 0.38 0.08

Frame A B C D E.F R.RS S.ST T.TU U

Quantity L/S 0.15 .025 .035 .045 .070 0.70 1.2 1.6 2.1



Note: R value in Table 1 is in the unit of Newton Series number 1 & 2 should be the pulley of pump and motor in Fig.16. As Vee-belt is being adjusted to final pretension the maximum load will be on Vee-belt. It is the best that pretension will be minimal. After adjustment, recheck the normal rotation of impeller. If any possible, start the pump by clean water before pumping slurry, open valve in suction pipe to check the pressure and flow rate of outlet. Check the leakage from the gland. If leakage is insufficient and gland shows signs of heating, then try loosening glad nuts to make the leakage a little much. The leakage should be adjusted to a given value until shaft is engaged with the packing.

b) Operation i. Periodically check pressure and quantity of sealing water and adjust packing

gland in time or replace packing rings to maintain a small amount of clean water leakage along the shaft. ii. Check bearing assembly at regular intervals for operation condition. If the

bearing shows heating at beginning the pump should be stopped. Then restart the



pump. If the bearing continues to heat up and temperature continues to rise, the bearing assembly should be opened to check. In general, bearing heating is caused by over-quantity of grease and impurities in the grease, the lubricant of bearing should be correct quantity and clean. The lubricant should be added periodically.

iii. Pump performance and efficiency will decrease as the clearance between the impeller and frame plate liner increases. Therefore, impeller should be adjusted forward in time in order to keep the certain clearance and to maintain pump operation in high efficiency.

Wearing parts should be placed when the performance of a given pump no longer satisfies the

requirements of a particular installation. It is recommended that the pump be opened at

regular intervals to determine the remaining life of wearing parts.

c) Shutting down Whenever possible the pump should be allowed to operate on water only for a short period to clear any slurry through the system before shut down. Then shut down the pump, valves and gland sealing water.

6. Maintenance For long trouble-free service with minimal amount of maintenance it is a must to pay attention to following items. i. Shaft Seal Care

In gland sealed pump, periodically check gland seal water supply and pressure. Always maintain a small amount of clean water leakage along the shaft by regularly adjusting the gland. When gland adjustment is no longer possible replace full packing. Quantity and pressure of sealing water should be corresponding with the above mentioned requirements. In centrifugal sealed pumps lubricate the packing and lip ring regularly by means of the grease cup. ii. Impeller Adjustment Pump performance changes inversely with the clearance existing between an impeller and the intake side liner. For the pump high efficiency operation the clearance between the impeller and the liner must be adjusted. In metal pump the clearance between the impeller and the frame plate liner should be 0.5-1mm. In rubber liner pump the clearance between an impeller and front & back liner should be equal. Firstly stop the pump when adjusting the clearance. Rotate shaft clockwise by hand and move bearing assembly forwards by tightening rear nut until the impeller starts to rub on front liner. For metal lined pumps, release the nut just tightened by half a turn, then move bearing assembly back by means of front nut until housing lug touches rear nut and the clearance will be 0.5-1mm. For rubber lined



pumps, release fully rear nut, rotate shaft clockwise by hand and move bearing assembly back by means of front nut until impeller starts to the back of the end cover. Calculate the average distance and adjust the bearing assembly forward to this distance to be sure of the correct clearance between impeller and front & back liner. After adjustment, check the impeller rotation again and tighten clamp bolts and both adjust screw nuts before starting up the pump. Then start up the pump. iii. Bearing Lubrication A correctly assembles and pre-greased bearing assembly as well as adequate maintenance will have a long trouble-free life. Maintenance personnel should open the bearing housings at regular intervals (not longer than twelve months) to inspect bearing and grease. The frequency and amount of lubricant to be added periodically depends upon a number of factors and a combination of them, including speed and size of bearing, duration and extent on-off operation, and the usual environment condition such as ambient and operating temperature and so on. Bearing heating will be caused by over-lubricating; therefore, adjustment and experience should be the final determining factors in establishing routine lubrication procedures. Refer to the following table and lubricate accordingly. iv. Spare pumps should be turned in a quarter turn so that the bearing may support

static load and vibration from outside evenly.

Note: Above mentioned is only suitable for the normal operating conditions and intended as a guideline only.



Above mentioned lubricants are used for bearing. For the bearing assemblies plugs inside bearing assembly are used for adding lubricant into the bearings and grease cup outside for cleaning labyrinths.

7. Troubleshooting

Faults Reason Removal

Pump fails to

discharge any liquid.

Air leaking into suction or gland.

Incorrect direction of pump rotation &

impeller worn.

Suction pipe blocked.

Sealed leakage.

Check direction of rotation

and replacing impeller.

Removal of blockage.

Shaft power

consumption is

excessive.

Gland excessively tightened against

packing rings.

Rotating component rubbing on a

stationary part.

Bearings worn.

Drive belt tension too tight.

Flow rate too large.

Pump speed & ratio too high.

Misalignment or unparalleled drive shaft

and pump shaft.

Loosen gland bolts.

Removal of the rubber part.

Replace the bearing.

Adjusting the belt.

Modifying the pump duty

and speed.

Adjusting the drive & pump

shaft.

Bearing is over

heating.

Lubricants too much or too less.

Containing impurities in the lubricant.

Bearing worn.

Lubricating as required.

Replace lubricant.

Replace bearing.

Bearing has short life

span.

Misalignment or unparalleled drive &

pump shaft.

Shaft bent.

Impeller unbalanced due to wear.

Foreign object entered into the bearing

or insufficient lubrication.

Incorrect procedure followed in fitting

bearings.

Adjust drive & pump shaft.

Replace shaft.

Replace impeller.

Clean the bearing.

Replace or refit the

bearings.

Excessive leakage

from stuffing box.

Packing rings excessively worn.

Shaft sleeve worn.

Dirty sealing water.

Replace new packing rings.

Replace shaft sleeve.

Change clean sealing water.

Pump vibrates or is

noisy.

Bearing worn.

Impeller unbalanced.

Air entered into suction pip or blocked.

Flow rate no-uniform and pump not

primed.

Replaced by new bearings.

Replaced by new impeller.

Discharge air and remove

block.

Improve on the pump

feeding.



21 Ginger St, Paget Mackay Qld Australia 4740

PO Box 5709, Mackay MC Qld Australia 4741

Ph: +61 07 4998 5070 Fax: +61 07 4952 1944

Email: [email protected]

ABN 17 154 031 802

As Price Pumps Australia’s policy is one of constant improvement, we reserve the right to

make specification changes without notice and without incurring liability

Price Pumps Installation and Operation...

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