Weir WARMAN AH Manuals

Manuals and User Guides for Weir WARMAN AH. We have 1 Weir WARMAN AH manual available for free PDF download: Installation, Operation & Maintenance Manual

Weir WARMAN AH Installation, Operation & Maintenance Manual (153 pages)

Centrifugal Slurry Pumps

Brand: Weir | Category: Water Pump | Size: 9 MB

Revision Page
3
Table of Contents
4
Introduction
12
Scope of the Manual
12
Intended Audience
12
Disclaimer
12
Overview of the Manual
13
Contact Information
13
Table 1-1: Overview of the Manual
13
Glossary of Abbreviation
14
Table 1-2: Abbreviations
14
Safety
15
Safety Symbols
15
Important Information
15
Table 2-1: Safety Symbols
15
Operating Conditions
18
Efficient Use and Intended Use
19
General Safety
19
Qualified Workers
19
Safe Working on Pumps
20
Sharp Edges
20
Markings and Approvals
20
Safety Equipment
20
Rotating Parts
20
Gland Adjustment
21
Fire Fighting
21
Emergency Procedures
21
Blocked Impeller
21
Transport and Storage
22
Transportation
22
Transport Safety
22
Chain of Responsibility
23
Load Restraint
23
Load Restraint Tools
24
Shaft Locking
24
Figure 3-2: Over-Centre Load Chain Binder
24
Figure 3-3: Attach Shaft Clamp
25
Figure 3-4: Fix Set Screw
25
Tie-Down Instructions
26
Lifting Instructions
26
Pump Storage
26
Maintenance Schedule
27
Standard Instructions
27
Medium-Term Storage
27
Hazardous Chemicals
28
Long-Term Storage
29
Prior to Start-Up
29
Technical Data
30
Pump Identification
30
Figure 4-1: Pump Identification Markings
30
Table 4-1: Pump Identification Code
30
Discharge Positions
31
Pump Nameplate
31
Pump Size
31
Figure 4-2: Discharge Position
31
Table 4-2: Pump Size - Metric
31
Table 4-3: Pump Size - Imperial
31
Table 4-4: Pump Size Grouping
31
Pump Part Identification
32
Bearing Power Requirements
32
Figure 4-3: Pump Part Identification - Example
32
Table 4-5: Power Rating - Basic Bearing Assembly
32
Tightening Torques
33
Table 4-6: Power Rating - Modified Basic Bearing Assembly
33
Table 4-7: Torque Settings for Cover Plate Bolts
33
Table 4-8: Torque Settings for Metric Bolts
33
Materials
34
Table 4-9: Torque Settings for Bearing Housing Clamp Bolts
34
Table 4-10: Torque Settings for Impeller Release Collar
34
Table 4-11: Material Types
35
Description
36
Introduction to AH Pump
36
Figure 5-1: Basic Pump
37
Pump Component Description
38
Drive Configurations
38
Figure 5-2: Examples of Drive Configurations
38
Bearing Assemblies and Frames
39
Oil Filled Bearing Assembly - Difference between K and KH Assemblies
39
Shaft Seals
39
Table 5-1: Range of Imperial and Metric Bearing Assembly Sizes
39
Liners
40
Table 5-2: Standard Pump Liner Fit-Up (Regardless of Frame)
40
Installation
41
Installation Safety
41
Pump
41
Pump Working Envelope
41
Foundations
42
Align and Grout the Warman Baseplates
42
Figure 6-1: Complete Pump Unit Working Envelope
42
Mount the Pump Base on a Steel Framework
43
Shaft Unlocking
43
Figure 6-2: Example of Aligning and Grouting Warman Baseplate
43
Shaft Alignment
44
Alignment, Tensioning, and Adjustment of Vee-Belt Drives
44
Figure 6-3: Set Screw and Shaft Clamp Location
44
Alignment
45
Tensioning
45
Figure 6-4: Shaft and Pulley Alignment
45
Adjustment
46
Figure 6-5: Vee-Belt Tensioning
46
Alignment of Direct-Coupled Pumps
47
Table 6-1: Vee-Belt Tensioning Force Requirements
47
Angular Shaft Alignment
48
Radial Shaft Alignment
48
Tolerances
48
Pipework
49
Observations
49
Figure 6-6: Angular and Radial Shaft Alignment
49
Flanges
50
Figure 6-7: Concentric (Not Recommended)
50
Figure 6-8: Eccentric (Recommended)
50
Figure 6-9: Bolting Sequence
50
Figure 6-10: Flange Loading
51
Table 6-2: Allowable Loads on Flanges
53
Intake Conditions
54
Oil Filled Bearing Assembly - K and KH
54
HGK005M, HGK205M, and TK005-1M
54
Before Start-Up
54
FFKS005-1 with Single (Full) Duo-Cone Seal
55
Before Start-Up
55
Figure 6-11: Preferred Piping Arrangement
55
Commissioning
56
Commissioning Safety
56
Commissioning Steps
57
Figure 7-1: Remove Set Screw
57
Figure 7-2: Rotate Shaft Clamp
58
Gland Adjustment
59
Avoidance of Impeller Loosening - Runback and Reverse Rotation
60
Correct Direction of Rotation and Input Torque Via Pump Shaft
60
Figure 7-3: Impeller Tightening
60
Incorrect Direction of Rotation and Input Torque Via Pump Shaft
61
Pump Shut down on High Static Discharge Heads
61
Figure 7-4: Rotation Direction Arrow Shown on Pump Casing
61
Effects of Unrestricted Runback and Reverse Rotation
62
Motor Rotation Check (Jog Test)
62
Gland Seal
64
Figure 7-6: Example of some Gland Seal Arrangements
64
GSW Flow and Pressure Requirements
65
Gland Adjustment
65
GSW Control Devices
66
Requirements for GSW Quality
66
Table 7-1: Minimum Total GSW Flows (L/Min)
66
HS Centrifugal Seal
67
Table 7-2: Flush Water Flow Rates (L/Min)
67
Figure 7-7: Type HS Centrifugal Seal Assembly
68
Figure 7-8: Warman Pump with HS Components
68
Mechanical Seal
69
Impeller Adjustment
69
Drive Alignment
69
Table 7-3: Bearing Housing Clamp Bolt Torque
70
Tightening Nuts and Bolts
71
Labyrinth Grease Purging
71
Bearing Assembly Lubrication
71
Lubricant Usage
71
Operation
72
Operation Safety
72
Shaft Seal
73
Priming
73
Normal Pump Start-Up
74
Blocked Impeller
74
Over-Pressure
74
Abnormal Start-Up
75
Blocked Intake Pipe
75
Air Entering Gland
75
Operating Faults
76
Overloading
76
Low Pit Level
76
Blocked Intake Pipe
76
Blocked Impeller
76
Blocked Discharge Pipe
76
Pump Shut down
77
Glands
77
Bearing and Impeller Tip Speeds
77
Impeller Adjustment
78
Maximum Allowable Pressures
78
Table 8-1: Series a Slurry Pumps (Type AH)
79
Bearing Fault Frequencies for Conditioning Monitoring
80
Oil Filled Bearing Assembly - K and KH
80
HGK005M, HGK205M, and TK005-1M
80
8.13.1.1 Start-Up
80
8.13.1.2 Operation Maintenance
80
FFKS005-1 with Single (Full) Duo-Cone Seal
80
8.13.2.1 Operation Maintenance
81
Maintenance
82
Maintenance Safety
82
Maintenance Check Points
83
Running Maintenance
83
Figure 7-9: Impeller Adjustment
83
Figure 9-1: Check Points for Periodic Maintenance
83
Gland Adjustment
84
Repacking Gland
84
Table 9-1: Commissioning and Maintenance Schedule
84
Tightening Nuts and Bolts
85
Labyrinth Grease Purging
85
Pump Disassembly
86
Table 10-1: Recommended Bearing Grease Characteristics
91
Table 10-2: Heavy Duty Bearing Assembly - Initial Grease Fill Quantities
91
Table 10-5: Lubrication Intervals - Heavy Duty Bearing Assembly
94
Table 10-6: Lubrication Intervals - Basic Bearing Assembly
95
Table 10-7: Lubrication Intervals - Modified Basic Bearing Assemblies
96
Table 10-8: Grease Quantities for Labyrinth Grease Purging
98
Figure 10-2: Thrust Rib
99
Figure 10-3: Components and Disposition of Grease in FFX Bearing Assembly with Single Drive-End Bearing
100
Seal Flushing
100
Table 10-9: Lubricant Specifications - HGK005M, HGK205M and TK005-1M
101
Table 10-10: Lubricant Specifications - FFKS005-1 with Single (Full) Duo-Cone Seal
101
Table 10-11: Grease Quantities for Labyrinth Grease Purging
101
Table 10-12: Oil Service Intervals
102
Table 10-13: Oil Quantities
102
Recommended Lubricants
103
Decommissioning and Disposal
104
Hazardous Chemicals
105
Troubleshooting
108
Table 12-1: Troubleshooting Packed Gland Seal Problems
109
Table 12-2: Troubleshooting Mechanical Seal Problems
110
Mechanical Seals
110
Special Tools
115
Figure 13-1: Piston Ring Compressor
115
Figure 13-2: Locating Nut
116
Figure 13-3: C-Spanner
116
Figure 13-4: Shaft Wrench
117
Tie-Down Instructions
118
Lifting Instructions
123
Stuffing Box
126
Cover Plate
133
Suction Cover
134
Baseplate Assembly
137
Figure 14-1: Pump with Gear Box Housings
152
Genuine Parts
153

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Weir WARMAN AH Installation, Operation & Maintenance Manual (153 pages)

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