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Summary of Contents for Metso Orion Series
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Operation & Maintenance Manual The Orion Series of Horizontal Slurry Pumps MM200 EHC-D Pump No 25411801001/A5684, 25411801002/A5685 Supplier / Order Nr Metso Minerals (UK) Ltd. / 110546 Customer Name Pigott Shaft Drilling Ltd. 2005-11-11 ed 2005-12-13...
Slurry Pump GENERAL About this manual Transport and storage Pump specification Customer service DESCRIPTION Product and warning signs Applications Design Materials and maximum working pressures Surface treatment General arrangement Performance curves Certificates & test results HEALTH & SAFETY DESCRIPTION OF OPERATION CONTROL SYSTEM INSTALLATION General...
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Slurry Pump OPERATING INSTRUCTIONS Starting Stopping Running checks CARE AND MAINTENANCE Safety measures Preventive maintenance & service schedule Tools and special equipment for service and maintenance Lubrication instructions Dismantling and assembly Setting pump clearances 9.5.1 Hydraulic parts and frame - removal and fitting 9.5.2 Shaft seal –...
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Slurry Pump 1.2.2 Handling and lifting Whether at the depot or on site, follow normal handling and lifting procedures and ALWAYS instructions contained or referred to in this manual. Handling of centrifugal pumps requires great care, especially larger or more cumbersome items of machinery.
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Slurry Pump 1.2.3 General storage instructions • Re-apply rust inhibitor to all moving parts, at least, every two months. Protect pump against dust and weather by storage indoors or under weatherproof cover Protect pump against impact Turn shaft at least every month WH03AA1AAA0en_03b.doc 04-W08 General...
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Slurry Pump 1.2.4 Long-term field storage Minimum requirement for storage and maintenance of centrifugal type pumps on site before their installation and start-up. Medium term storage Indoor storage of equipment is recommended in order to prevent the harmful effects of exposed conditions, particularly in dust laden atmospheres.
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This work may be done by Metso Minerals and charged to the purchaser under normal rates in force at the time the service is carried out.
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Slurry Pump To ensure rubber products maintain their original properties, storage conditions must be controlled. Where practicable, ensure rubber products are: kept sealed in their original packing which should be opaque; kept away from direct sunlight; kept away from electrical machinery -e.g. motors and generators; kept in a cool, dry environment between 15°...
Slurry Pump Customer service For any inquiry regarding the servicing and repair of Metso Minerals Slurry pumps please contact the local Metso Minerals Branch. For information on the Metso Minerals Branch closest to you, contact one of the Metso Minerals Global Sites listed below: Metso Minerals (Sala) AB Norrängsgatan 2...
Slurry Pump DESCRIPTION Product and warning signs 2.1.1 Product signs All product signs attached to the pump are shown below. Motor weight Drive weight Pump weight Total weight Figure 2.1.1-1 Weight plate The weight sign is mounted next to the machine sign. When the pump is supplied without motor and drive, only the weight of the pump is stamped on the sign.
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Slurry Pump 2.1.2 Warning and caution signs This sign, attached to the drive cover, indicates the direction of rotation of the pump when viewed from the drive end. THERE IS RISK OF SERIOUS DAMAGE TO THE PUMP IF IT IS ALLOWED TO ROTATE IN THE WRONG DIRECTION This sign is a hazard warning and is usually accompanied by text indicating the nature of the hazard.
Slurry Pump Applications The Metso Minerals Slurry Pump has been designed for a wide variety of abrasive pumping duties. While the pumps may be used in many different industries, they are all designed for constant use in the most arduous conditions. These high-efficiency pumps are of a simple design, providing ease of maintenance and facilitating replacement of wearing parts.
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Slurry Pump 2.3.2 Noise level In certain installations and outside the optimum operating conditions, the noise level of 70 dB(A) may be exceeded. The motor generates most of the noise and, in general, the noise level for properly designed installations will be about 2dB(A) above that of the motor. 2.3.3 Vibration The pumps are in ClassIV as described in ISO10816-1.
Slurry Pump Materials and maximum working pressures Metso Minerals Slurry Pumps are constructed from materials selected to give excellent wear characteristics over the full range of pumping duties. This section lists the materials of construction and working pressures for STANDARD duty applications.
Slurry Pump Surface treatment 2.5.1 Standard finish The external surfaces of the pump are protected by the anti-corrosive system specified in Table 2.5.1-1, except exposed machined surfaces which are coated with an air drying rust inhibitor. Drive motors are supplied in the original manufacturer’s standard finish. Stainless steel, plastic or elastomeric parts are not painted.
Pump MM200 C5 Performance curve Full impeller dia Vane diameter Vane config Impeller type No. of vanes Max sphere Impeller material Liner material Full Closed Metal Metal 1800 r/min 1700 1600 1500 1400 H (m) 1300 1200 1100 10,00 m 1000 8,00 m 6,00 m...
Slurry Pump Certificates and test results DECLARATION BY THE MANUFACTURER PROHIBITION TO PUT INTO SERVICE We Metso Minerals (Sala) AB, Norrängsgatan 2, 733 25 SALA, SWEDEN declare that the slurry pump Manufacturer Metso Minerals (Sala) AB Pump type MM200 EHC-D...
It is strongly recommended that all customers' production and maintenance personnel and site visitors are made fully aware of potential dangers of this equipment. If any doubt exists, please contact Metso Minerals for advice. FOR YOUR OWN PERSONAL SAFETY READ AND TAKE NOTE OF THE FOLLOWING...
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Slurry Pump - Make sure that slings, shackles, etc. are of LIFTING THE PUMP adequate load carrying capacity. Metso Minerals Slurry pumps may be provided with lifting eyes designed for lifting individual components. These should be used to lift the pump unit or the pump set.
Slurry Pump DESCRIPTION OF OPERATION General Centrifugal pumps work best with minimum wear and other mechanical stress if the operating point is close to the pump's best efficiency point (BEP). To choose a pump that works close to its best efficiency line (BEL), it is important to understand how the pump interacts with the piping system in which it is installed.
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Slurry Pump When the pump operates at When the pump's flow The magnitude of the radial best efficiency point, uniform capacity is not utilized, force F is greatest when the pressure is obtained in the uniform pressure in the pump runs against closed casing which in its turn pump casing will not be valve = 0 flow.
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Slurry Pump The way in which the hydraulic work is affected when the pump does not operate at BEP is shown in Figure 4.3-2 and Figure 4.3-3 This is of decisive importance in slurry pumping. Impeller vane inlet Pump casing nose Figure 4.3-2 Operating outside BEP - At low load 3.
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Slurry Pump Hydraulic efficiency is a function of hydraulic turbulence - the more turbulence, the less efficiency. In slurry pumping, a high level of efficiency is therefore important. Little hydraulic turbulence is formed at BEP and the abrasion is chiefly of a sliding nature, since the differential pressure is low when the slurry passes through the impeller and pump casing.
Each installation is, therefore, a special case needing careful examination of its particular requirements. The following are general guidelines for preparing a foundation for Metso Slurry Pumps –refer to Figure 6.2-1 for details.
Apart from suitable lifting equipment, a standard fitter's tool kit together with suitably-sized hexagon key wrenches and torque wrenches are normally sufficient to install the pump. See Toolkit, sub-section 10.6. Metso Minerals can supply all recommended fixtures and tools at additional cost. WH15AM1AAA0EN_06B.DOC 05-W02...
Slurry Pump Installation procedure 6.4.1 Pump When the foundation has fully cured, the anchor bolts may be installed –refer to Figure 6.2-1 and Figure 6.4-1. Spacing between anchor fixings should normally be more than 10 times their diameter, unless otherwise instructed. Refer to manufacturer’s instructions for specific details.
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Slurry Pump 6.4.2 Belt driven pumps Make allowances for possible pump shaft forward adjustment when positioning the drive pulley on the shaft. Align the pump and motor pulleys correctly. Misalignment between pulleys could cause excessive belt wear, heat generation and noise. 6.4.3 Direct driven pumps Where practicable, fit a spacer coupling so that the pump "back pull-out"...
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Slurry Pump Connect the gland water supply pipe, in case of pumps with a water flush gland seal. Water must be clean, and at the correct pressure and flow rate. See Table 6.4.4-1 and section 9.5.3. Recommended water quality for flushed gland 6.5 to 8 Dissolved solids <...
DO NOT INSTALL THE PIPEWORK IN SUCH A WAY THAT IT PUTS ANY EXCESSIVE LOAD ONTO THE 6.5-1 PUMP CASE ABLE INDICATES THE STANDARD ALLOWABLE FLANGE FORCES PLEASE CONSULT METSO MINERALS SHOULD THE FLANGE LOAD REQUIREMENT BE GREATER FLANGE SIZE AND F AND M (Nm) (Nm)
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Slurry Pump Q(m /s) < < 2min (4 × D) < < (10 × D) V(m ) 45º-60º Figure 6.5-1 Recommendations for pipework layout The pump is self-priming, which means that the pump case must be full of liquid before the pump is started. Additionally, take note of the following (see also Figure 6.5-1): •...
Slurry Pump • A drain valve should be incorporated in the inlet pipe. A floor channel should also be provided directly beneath it for recovering the waste slurry. • Secure the pump inlet and outlet pipes separately to avoid unnecessary transmission of vibrations, forces or moments to the pump.
Slurry Pump COMMISSIONING WARNING BEFORE CARRYING OUT THE FOLLOWING CHECKS ISOLATE THE ELECTRICAL SUPPLY TO THE MOTOR If the pipework has not been connected to the pump on installation, ensure that the pump case and associated pipework are clear of any construction debris, slurry etc. before connection.
Slurry Pump OPERATING INSTRUCTIONS Start-up If the pump has just been maintained or has not been put into operation for some time, then carry out the pre-start checks as described in Commissioning, section 7. Open the pump inlet and outlet valves. Check for leakage from the inlet and outlet connections.
Slurry Pump • For short stoppage periods and where there is risk of the slurry settling out, or ONLY solidifying in the system: Pumps with expeller seal - immediately after shutting down, close the isolation valves and then drain the pump and the sump, if necessary.
Slurry Pump CARE AND MAINTENANCE Safety measures WARNINGS ISOLATE THE PUMP FROM ALL SOURCES OF ELECTRICITY AND POWER BEFORE COMMENCING ANY MAINTENANCE WORK ALWAYS ASCERTAIN THE NATURE OF THE PROCESS LIQUID BEFORE COMMENCING WORK ON A PUMP AND FOLLOW THE HEALTH AND SAFETY PROCEDURES RELEVANT TO THE PROCESS LIQUID MAY BE HARMFUL TO HEALTH Should the process liquid be of a harmful or hazardous nature take the following precautions as a minimum;...
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Slurry Pump RUNNING HOURS ITEM ACTION 100 250 1000 × Water flushing gland seal. Check stuffing box connection for leaks. Rectify as necessary. × Centrifugal Gland Seal Tighten gland follower screws or renew seal as necessary. Lubricate bearings. See section ×...
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Slurry Pump 9.2.2 Maintenance recommendations Metso Minerals recommends that the following actions are carried out prior to any maintenance: • clean down the pump, removing any accumulation of debris and/or slurry; • ensure that inlet and outlet pipeline valves, if fitted, are closed;...
Slurry Pump Tools and special equipment for service and maintenance NOTE THE FOLLOWING SPECIAL TOOLS ARE AVAILABLE FOR PUMPS WITH EITHER SINGLE DOUBLE ADJUSTMENT FRAMES A special crank-handle to fit over the drive-shaft end diameter and locate the drive key is advantageous when fitting the impeller to the shaft. See Dismantling and Fitting the Hydraulic Parts, section 9.5.2.
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Slurry Pump Two proprietary packing extractors to facilitate the removal of the packing will also be advantageous. Figure 9.3-2 Packing extractor Back-liners for large pumps are very heavy. Specially designed back-liner lifting tools allow safe handling of the components. Figure 9.3-3 Back-liner lifting tool for metal pumps WH16AM1TAA0EN_02A.DOC 04-W51 Care and maintenance...
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11.3) to lift the case assembly is required. CAUTION TO PREVENT DAMAGE ONLY USE A SOFT SLING STROP TO LIFT THE CASE All of the above special tools can be obtained from Metso Minerals. See section 10.6. WH16AM1TAA0EN_02A.DOC 04-W51 Care and maintenance...
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9.4.1 First-fill and re-packing after major servicing Metso Minerals Slurry pumps are lubricated with SKF LGMT3 before dispatch. When renewing or re-fitting the bearings, they must again be re-packed with grease of the same specification as detailed in Table 9.4.1-1. The required quantity for each bearing is specified in Table 9.4.1-2.
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Slurry Pump 9.4.2 Lubrication interval The bearings may be re-greased with any lithium-based grease that conforms to the specification detailed in Table 9.4.1-1. The lubrication interval depends upon the shaft speed and the bearing operating temperature, as shown in Table 9.4.2-1. Frame Grease Pump speed (rpm) Size...
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Slurry Pump 9.4.3 Lubrication points The pumps have two bearing lubrication points. See Figure 9.4.3-1. Part Position Qty.(cc) Frequency Lubricant See Table Bearing cylinder SKF LGMT3 or equivalent - Table 9.4.2-1. see Table 9.4.1-1. 9.4.2-1. Motor and/or See manufacturer’s instruction –...
Slurry Pump Dismantling and assembly 9.5.1 Setting pump clearances • Impeller clearance adjustment (Standard Slurry Impeller) These adjustments enable the back (frame side) and front (inlet side) running clearances to be kept to a minimum so that maximum operating efficiency is maintained throughout the wear life of the pump.
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Slurry Pump Unscrew the jack screws completely. Remove the case shim sets (P3). Reduce the gap between the bearing frame flanges and base/case support (P13) by evenly tightening two diametrically opposite case nuts (P1) and bolts (P4) until impeller (W3) touches case (W1). Measure the gap between the bearing frame and the base/case support .
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Slurry Pump 9.5.2 Hydraulic parts and frame - dismantling and fitting Opening and closing the pump – fixed base WARNING MAKE SURE THAT ALL SLINGS SHACKLES ARE OF ADEQUATE LOAD CARRYING CAPACITY APPROXIMATE WEIGHTS OF MAJOR COMPONENTS ARE PROVIDED IN SUB SECTION 11.3 LIFTING POINTS INCORPORATED IN INDIVIDUAL COMPONENTS ARE INTENDED SOLELY FOR LIFTING...
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Slurry Pump Shims (P) between the case and bearing frame are used to adjust the front running clearance between the impeller and the case. For ease of assembly, case fixings (B) locate in slots around the frame's front flange. The inner flange of the frame provides a spigot for an expeller ring or a stuffing box.
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Slurry Pump Isolate the drive motor and attach suitable warning plates to the relevant switches. It is advisable to remove the fuses and/or lock the isolator open to prevent accidental starting. Where fitted, a mechanical seal requires setting for disassembly and section 9.5.3 would provide the relevant instructions.
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Slurry Pump Closing the pump If the Front Pull-Out Method was used: i/ Lift and push the case over impeller (W3), onto back-liner (W4) and against the vertical plate. Ensure that case fixings (B) enter their respective holes around the flange joint. ii/ Locate and secure the case to the vertical plate by fitting the upper and lower casing clamp fixings (C) in the case slots provided.
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Slurry Pump 9.5.2 Hydraulic parts and frame - dismantling and fitting (ii) Wet-end - disassembly and reassembly General Case (W1), impeller (W3) and back-liner (W4) are high quality, high-chrome iron castings. Larger size pump cases are ribbed and incorporate a number of lifting lugs. The inlet and outlet branches are fitted with joint seals (F2, F4) and split flanges (F1, F3) to provide a leak-proof and secure pipework connection.
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Slurry Pump Remove nuts (W20) from the four back liner bolts (W19) and withdraw back liner (W4). The bolts are retained in position by a rubber strap. WARNING BACK LINERS ON LARGE PUMPS ARE EXTREMELY HEAVY USE THE BACK LINER LIFTING TOOL RECOMMENDED IN SECTION Inspection Clean and inspect case (W1), impeller (W3) and back-liner (W4) for severe...
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Slurry Pump 9.5.2 Hydraulic parts and frame - dismantling and fitting (iii) Impeller Release Mechanism (IRM) – type-1 An IRM (a) is fitted behind the shaft sleeve (b) to ease removal of the impeller during maintenance and repair. Removing this mechanism releases the tightening torque on the impeller.
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Slurry Pump Refer to Figure 9.5.2-ii: To dismantle IRM (B25), loosen its clamping bolt. This should make it spring open. To assemble IRM (B25): apply an anti-seize compound to the IRM assembly screw threads; ensure that the IRM clamping bolt is tightened up, and that IRM (B25) and impeller spacer (B54) fit together correctly -i.e.
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Slurry Pump 9.5.2 Hydraulic parts and frame - dismantling and fitting (iv) Hydraulic system Not applicable WH18HYDAAA0EN_01D.DOC 04-W08 Care and maintenance...
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Slurry Pump 9.5.3 Shaft seal - dismantling and fitting • Centrifugal Seal (High-Chrome Expeller Ring) The centrifugal seal is used in pumping installations where water flushed glands are not acceptable. A vaned expeller (G15) mounted on the shaft between the impeller and shaft sleeve (G2) generates a head that, working in conjunction with the back vanes of impeller (W3), keeps the liquid away from packing (G5).
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Slurry Pump If the centrifugal seal leaks when the pump is stationary, tighten gland follower (G10) by means of the gland follower screws (G18). CAUTION DO NOT OVER TIGHTEN THE SCREWS AS THIS WILL CAUSE SEVERE WEAR OF THE SHAFT SLEEVE Routine Adjustments Apart from the running checks specified above the only routine adjustments required are: To check the gland for leakage on stopping the pump and to adjust as...
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Slurry Pump Smear three new packing rings with grease and then insert into expeller ring (G7); one turn of packing (G5), lantern ring (G1), the last two packing rings, followed by gland follower (G10). 180° NOTE MAKE SURE THAT THE PACKING JOINTS ARE STAGGERED BY APPROXIMATELY 9.5.3-1).
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Slurry Pump Maintenance of the Centrifugal Seal (Assembly) NOTE ALL PACKING RINGS AND ANY SUSPECT COMPONENTS SHOULD BE RENEWED If expeller ring seal (G17.1) is to be renewed, remove the old seal and thoroughly degrease the groove in expeller ring (G7) using a suitable cleaning agent.
Slurry Pump 9.5.4 Shaft and bearing assembly - removal and fitting The following instructions assume that the pump is installed complete with the drive unit and is connected to the suction and discharge pipework. Removal Remove the drive safety guard and disconnect the drive belts or drive coupling as applicable.
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Slurry Pump Fit the grease nipple (B13) to the end-cover at the wet-end of the shaft. Where applicable, assemble impeller release mechanism to the shaft – see section 9.5.2 (iii). Reassemble the gland. Reassemble the remainder of the pump. WH201A1B010EN_01E.DOC 04-W08 Care and maintenance...
Slurry Pump 9.5.5 Shaft and bearings - disassembly and re-assembly General The bearing assembly consists of a steel shaft onto the end of which the impeller is screwed. The other end of the shaft is keyed to accept a coupling or belt drive arrangement.
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Slurry Pump Table 9.5.5-1 Bearing assembly type colour coding UNIT TYPE STATUS COLOUR CODE Standard New build Mid Blue-18.E.53 Double dry-end New build Green Double wet-end New build Yellow Standard Reconditioned Double dry-end Reconditioned Red with green band Double wet-end Reconditioned Red with yellow band Disassembly...
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Slurry Pump Carefully inspect the roller bearings, cages and races for wear, damage and corrosion. After inspection, dip the bearings in gear oil and wrap them in a clean cloth or paper to protect them until installation. Check the condition of the shims. Examine the shaft for damage and corrosion.
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Slurry Pump grease hole will be accessible when the bearing cylinder assembly is fitted to bearing frame (P14). Tighten the screws (B5) evenly and to the correct torque. See Torque Table, section 11.1. Fit shaft (B11) into bearing cylinder housing (B14) with its threaded end protruding from the wet-end cover (B2.1).
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Slurry Pump Table 9.5.5-2 Bearing clearances FRAME SIZE CLEARANCE FLOAT FR250 0.075 to 0.125 FR300 0.075 to 0.125 FR400 0.100 to 0.150 FR500 0.100 to 0.150 FR600 0.150 to 0.200 FR750 0.180 to 0.250 Check the bearing clearance for the size of pump (See Table 9.5.5-2) using a dial test indicator on the shaft end.
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Slurry Pump 9.5.6 Pump drive - removal and re-fitting (NOT APPLICABLE) WH21AAAD000EN_03B.DOC 04-W08 Care and maintenance...
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A multimeter, a test lamp and appropriate circuit diagrams will be required to carry out checks on electrical equipment. NOTE IF ALL FAILS CONTACT METSO MINERALS FOR FURTHER ADVICE 9.6.2 Pump fails to start Is power supply live ? No⇒ Check that: •...
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Slurry Pump 9.6.3 The pump starts but the motor protection trips Has flow path or pipe run been Yes⇒ modified ? • Alter the flow path or pipe run, or adjust the rating of the drive motor and pump to suit ⇓...
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Slurry Pump 9.6.5 The pump runs unevenly or vibrates Is the inlet flow uneven or is the pump drawing air ? Yes⇒ • Either adjust the feed to the pump, or adjust the rating of the drive, motor and pump to ⇓...
• Build Number • Approximate date of purchase • Part Number and Description of Required Spare Parts This information should then be forwarded to the local Metso Minerals branch for action - - see sub-section 1.4. WH23AM1S010EN_03C.DOC 04-W08 Spare parts...
Pump MM200 EXP HC Parts list Item Part No. Description Qty Unit weight Wear parts PDCH2176 Case 204.00 PDCH2178 Impeller 55.00 PD721041 Back liner 27.00 SA983300 O-ring (incl. in w04) 0.00 Shaft seal PD730063 Lantern ring 0.00 PDCF2539 Shaft sleeve 1.90 PD730011 Packing...
Slurry Pump 10.6 Toolkit 10.6.1 Standard tools In addition to the special tools detailed in sub-section 9.3 and Table 10.6-2, and installation tools and equipment detailed in sub-section 6.3, Table 10.6-1 lists a basic toolkit for performing normal maintenance operations on the pump. A dial test indicator may also be required to set bearing clearances –...
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