Manual de instalação, operação e manutenção Installation ... · This manual with its user and safety instructions is an integral part of the pump delivery and must be kept in

Weir Minerals Netherlands b.v.

P.O. Box 249, NL-5900 AE Venlo, the Netherlands Egtenrayseweg 9, NL-5928 PH Venlo, the Netherlands

4495 Registration No.: 12032525

Tel: +31(0)77 3895200 Fax: +31(0)77 3824844 Email: [email protected] WWW: http://www.weirminerals.com

Copyright © Weir Minerals Netherlands b.v. 2011.

A Weir Minerals Netherlands b.v. é proprietária do copyright, coincidente com as instruções e ilustrações contidas no presente manual. Todo o material contido no presente manual goza a proteção da lei de direitos autorais, de tratados internacionais e das leis aplicáveis do país no qual ele for usado. O material não deve ser usado, reproduzido ou copiado ao todo ou em partes, de qualquer formato ou por qualquer meio, nem podem as informações contidas no mesmo, sendo confidenciais da Weir Minerals Netherlands, ser disponibilizados a qualquer pessoa que seja sem a prévia autorização por escrito da Weir Minerals Netherlands b.v. Além disto, você não está permitido a alugar, sublincenciar ou emprestar o manual ou o seu conteúdo. O manual foi entregue e recebido sob a condição expressa para que ele seja utilizado somente para o propósito específico para o qual ele foi fornecido e não pode ser usado de outra forma que possa prejudicar ou causar perdas diretas ou indiretas para a Mineral Netherlands b.v. ou qualquer corporação correlacionada. Exclusão.

Com exceção dos casos onde a legislação proíbe expressamente a exclusão de direitos oriundos da garantia, a Weir Minerals Netherlands b.v. exclui todos os direitos de garantia em relação às instruções e aos desenhos, seja expressas ou supostas, incluindo, sem limitação, qualquer suposta garantia de comercialização, adequação para fins específicos, compatibilidade com qualquer sistema específico, ou integridade de dados, e o usuário assume total responsabilidade pelo uso do software utilizado pelo sistema.

Copyright © Weir Minerals Netherlands b.v. 2011. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in the instructions and drawings stored in this manual. All material of this manual are protected by the Dutch Copyright Law, international treaty provisions and applicable laws in the country in which it is being used. The material must not be used, reproduced or copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v be disclosed to any person without the prior written permission of Weir Minerals Netherlands b.v. Furthermore you may not rent, lease, sublicense or lend the manual and its contents. The manual has been delivered and received on the express condition that it may be used only for the specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any related corporation. Disclaimer. Except to the extent legislation expressly prohibits the exclusion of provisions as to warranties, Weir Minerals Netherlands b.v. disclaims all warranties as to the instructions and drawings, whether express or implied, including without limitation any implied warranties of merchantability, fitness for a particular purpose, compatibility with any particular system, or data integrity and the user assumes all responsibility for the use of the software on its system.

EN = English "Original instructions" EN = Inglesa «manual original»

Manual de instalação, operação e manutenção

Installation, Operation and Maintenance Manual

Numéro de encomenda do cliente: Customer purchase order number: 20 B/112 (LOI 18/0313/07-IMP)

Numéro - nom do projeto WEIR: WEIR Project number - name: 201150 - CBA

Numéro da bomba: Pump number: GEHO 7201150/1+2

Tipo de bomba: Pump type: GEHO TZPM 2000

Numéro do documento: Document number: 201150-IOM-EN-R03

Preface

201150-IOM-EN-R03 1.1

Pos: 1.1 /GEHO/Heading/H1/#. Preface chapter 1 @ 0\mod_1133187936567_31.doc @ 111 @

1 Preface Pos: 1.2 /GEHO/Preface/General/Diaphragm pumps/Introduction @ 0\mod_1133188276656_31.doc @ 121 @

This pump is developed by Weir Minerals Netherlands b.v. Pos: 1.3 /GEHO/Preface/General/Common intro @ 0\mod_1139913202827_31.doc @ 2530 @

This manual with its user and safety instructions is an integral part of the pump delivery and must be kept in its neighborhood, accessible for reference at all times.

All persons involved in using and operating this pump and working at this pump must have read and understood this manual and must comply with it at all times.

We accept no responsibility for damage or disruption caused by disregard of this manual and its instructions.

Scope of this manual

This manual and its user instructions apply to the GEHO PUMPS equipment during: Pos: 1.4 /GEHO/Preface/General/Purpose - Final @ 0\mod_1139912839316_31.doc @ 2518 @

• Transport

• Installation

• Operation, start and stop procedure

• Maintenance Pos: 1.5 /GEHO/Preface/General/Use @ 0\mod_1133427209923_31.doc @ 246 @

This equipment, supplied by Weir Minerals Netherlands b.v, is only allowed to be used, according to and restricted to the technical data. Before exceeding the technical data, a written permission from Weir Minerals Netherlands b.v is required. Pos: 2 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @ Pos: 3 /GEHO/Heading/H2/#.# Revision form @ 0\mod_1133271476093_31.doc @ 213 @ 2

1.1 Revision form Pos: 4 /GEHO/Preface/Project/201150-EN- Revision form @ 6\mod_1233070872850_31.doc @ 46027 @

Rev. No. Chapter Description By Checked Date

EN-R00 Preliminary release. GHH FVO 27-01-2009

EN-R01 All Preliminary release, update details. GHH FVO 16-06-2009

EN-R02 All Preliminary release, update details. GHH FVO 21-03-2011

EN-R03 All Final, as built GHH FVO 05-05-2011

Pos: 5 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Contents

201150-IOM-EN-R03 2.1

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2 Contents

1 Preface ....................................................................................... 1.1

1.1 Revision form...............................................................................................1.1

2 Contents..................................................................................... 2.1

3 SAFETY...................................................................................... 3.1

3.1 Safety symbols ............................................................................................3.1

3.2 Important information.................................................................................3.2

3.3 Efficient use .................................................................................................3.3

3.4 Intended use ................................................................................................3.3

3.5 General safety instructions........................................................................3.3

3.6 Qualified workers ........................................................................................3.3

3.7 Safe working on the pump .........................................................................3.3

3.8 Safety equipment ........................................................................................3.4

3.8.1 Safety related documentation.................................................................................... 3.4

3.8.2 CE conformity ............................................................................................................ 3.4

3.8.3 "EMERGENCY STOP" button .................................................................................. 3.4

3.8.4 Safety covers and safety guards............................................................................... 3.5

4 Technical data ........................................................................... 4.1

4.1 Manufacturer information...........................................................................4.1

4.2 Customer information.................................................................................4.1

4.3 Manufacturer information...........................................................................4.1

4.4 Technical data..............................................................................................4.2

4.4.1 Operating characteristics........................................................................................... 4.2

4.4.2 Pump and project data and identification.................................................................. 4.3

4.5 Tightening torques......................................................................................4.7

4.5.1 General instructions................................................................................................... 4.7

4.5.2 General torques......................................................................................................... 4.7

4.5.3 Foundation bolt torques according to DIN 529 ......................................................... 4.7

4.5.4 Special torques.......................................................................................................... 4.8

4.6 Auxiliary connections and lubrication data ...........................................4.12

4.7 Drawings + lists + instruments ................................................................4.12

5 Description ................................................................................ 5.1

5.1 Introduction..................................................................................................5.1

5.2 Working principle ........................................................................................5.2

5.2.1 Numbering of the diaphragm housings..................................................................... 5.2

5.2.2 Typical flow of the GEHO TZPM pump..................................................................... 5.2

5.2.3 Suction stroke ............................................................................................................ 5.3

5.2.4 Discharge stroke........................................................................................................ 5.3

Contents

2.2 201150-IOM-EN-R03

5.3 Pump control system..................................................................................5.4

5.4 Drive unit ......................................................................................................5.4

5.5 Power end ....................................................................................................5.4

5.5.1 Lubrication unit ...........................................................................................................5.5

5.6 Liquid end ....................................................................................................5.5

5.6.1 The propelling liquid section.......................................................................................5.5

5.6.2 The slurry section .......................................................................................................5.5

5.6.3 Piston unit ...................................................................................................................5.6

5.6.4 Flushing unit ...............................................................................................................5.6

5.6.5 Propelling liquid control system..................................................................................5.7

5.6.6 Pressure limitation system .......................................................................................5.12

5.6.7 Diaphragm housing unit ...........................................................................................5.13

5.6.8 Suction valve unit .....................................................................................................5.13

5.6.9 Discharge valve unit .................................................................................................5.13

5.6.10 Suction air vessel unit...............................................................................................5.14

5.6.11 Discharge pulsation dampener ................................................................................5.15

6 Transport and installation ........................................................6.1

6.1 Transport and lifting ...................................................................................6.1

6.1.1 Weights and weight limits...........................................................................................6.1

6.2 Erecting the installation..............................................................................6.2

6.3 Hoisting instructions ..................................................................................6.2

6.3.1 General .......................................................................................................................6.2

6.3.2 Lifting eye bolts...........................................................................................................6.2

6.3.3 Smaller parts...............................................................................................................6.2

6.3.4 Transport the packed installation ...............................................................................6.3

6.3.5 Drive unit.....................................................................................................................6.3

6.3.6 Power end ..................................................................................................................6.4

6.3.7 Liquid end ...................................................................................................................6.4

6.4 Installation....................................................................................................6.5

6.4.1 Foundation..................................................................................................................6.5

6.4.2 Mount and level the pump..........................................................................................6.6

6.4.3 Auxiliary systems........................................................................................................6.7

6.4.4 Drive unit.....................................................................................................................6.8

6.5 Safety regulations and instructions for nitrogen...................................6.13

6.6 Pre-charging with nitrogen a pulsation dampener (discharge line)....6.14

6.6.1 Pre-charging the discharge pulsation dampener, set-point instructions .................6.14

6.6.2 Pre-charging a pulsation dampener with the nitrogen filling device ........................6.16

6.7 Pre-charging an accumulator with nitrogen ..........................................6.19

7 Operation, Start-up + Start + Stop procedures ......................7.1

7.1 Start-up, working with the GEHO + VFD main power switch OFF.........7.1

7.1.1 Initial lubrication filling.................................................................................................7.1

7.1.2 Propelling liquid ..........................................................................................................7.2

7.1.3 Air supply unit .............................................................................................................7.2

7.1.4 Pre-charging an accumulator.....................................................................................7.2

7.1.5 Procedure pre-charging a pulsation dampener with nitrogen ...................................7.2

Contents

201150-IOM-EN-R03 2.3

7.2 Start-up checklist, working with the GEHO main power switch ON......7.3

7.2.1 Main power switch ..................................................................................................... 7.3

7.2.2 Start-up, electrical check ........................................................................................... 7.3

7.2.3 Initial power end oil check ......................................................................................... 7.3

7.3 Start-up, priming procedure.......................................................................7.4

7.3.1 Priming the slurry section .......................................................................................... 7.4

7.3.2 Priming the propelling liquid section.......................................................................... 7.6

7.4 Operating the GEHO Touch Panel + GEHO Pump Control System ......7.8

7.4.1 Pump operation by local control at the "GEHO HMI PANEL" .................................. 7.8

7.4.2 Pump operation by remote control, supplied by others ............................................ 7.8

7.5 "START" procedures ..................................................................................7.9

7.5.1 Operation definitions.................................................................................................. 7.9

7.5.2 "PRE-START" check list.......................................................................................... 7.10

7.5.3 "PRE-START" working with the GEHO and "VFD" main power switch "ON"........ 7.10

7.5.4 "PRE-START" procedure, if "LOCAL" operated ..................................................... 7.11

7.5.5 "PRE-START" procedure, if "REMOTE" operated ................................................. 7.11

7.5.6 "START" procedure, if "LOCAL" operated.............................................................. 7.12

7.5.7 "START" procedure, if "REMOTE" operated .......................................................... 7.12

7.6 "STOP" procedures...................................................................................7.13

7.6.1 "EMERGENCY STOP" procedure .......................................................................... 7.13

7.6.2 "STOP" procedure, if "LOCAL" operated................................................................ 7.14

7.6.3 "STOP" procedure, if "REMOTE" operated ............................................................ 7.14

7.6.4 "STOP" procedure for flushing ................................................................................ 7.15

7.6.5 "STOP" procedure for maintenance........................................................................ 7.16

7.6.6 "STOP" procedure for "EXTENDED SHUT-DOWN".............................................. 7.18

8 Maintenance .............................................................................. 8.1

8.1 Maintenance safety instructions ...............................................................8.1

8.2 Maintenance: log book ...............................................................................8.2

8.3 Maintenance: references ............................................................................8.2

8.4 Maintenance: checkpoints of the pump drive components...................8.2

8.5 Maintenance: intervals................................................................................8.3

8.6 Maintenance: “Hot torque” after initial start-up.......................................8.8

8.7 Maintenance: checkpoints 200 hours after initial start-up .....................8.9

8.8 Maintenance: interval checkpoints .........................................................8.10

8.9 Lubrication system ...................................................................................8.17

8.9.1 Check the oil level.................................................................................................... 8.17

8.9.2 Oil filter clogging indicator........................................................................................ 8.17

8.10 Propelling liquid system...........................................................................8.18

8.10.1 Oil filter clogging indicator........................................................................................ 8.18

8.11 Gearbox maintenance...............................................................................8.19

8.11.1 Gearbox: oil filters.................................................................................................... 8.19

Contents

2.4 201150-IOM-EN-R03

9 Troubleshooting ........................................................................9.1

9.1 Trouble shooting.........................................................................................9.1

9.2 Trouble shooting at a diaphragm pulsation dampener ..........................9.7

9.3 Typical wear phenomena and its causes .................................................9.9

9.3.1 Valves .........................................................................................................................9.9

9.3.2 Pump diaphragm......................................................................................................9.10

9.3.3 Pulsation dampener diaphragm...............................................................................9.10

9.3.4 Piston........................................................................................................................9.11

9.3.5 Cylinder liner.............................................................................................................9.11

10 Assembly and disassembly ...................................................10.1

10.1 Safety instructions....................................................................................10.1

10.1.1 Lifting eye bolts.........................................................................................................10.2

10.2 Manual rotation of the pump crankshaft ................................................10.3

10.2.1 Manual rotation of the pump shaft with a socket wrench at the gearbox. ...............10.3

10.2.2 Balance position of the TZPM crank shaft ...............................................................10.5

10.3 Special tools ..............................................................................................10.6

10.3.1 Air driven hydraulic pump.........................................................................................10.6

10.3.2 Oil connector caps....................................................................................................10.6

10.4 Drive unit ....................................................................................................10.7

10.5 Frame unit ..................................................................................................10.7

10.6 Lubrication system ...................................................................................10.8

10.6.1 Environment instructions..........................................................................................10.8

10.6.2 Change the oil filter...................................................................................................10.8

10.6.3 Replace the pump lubrication oil and the oil suction filter inside the frame.............10.9

10.6.4 Replace the venting filter at the pump power end ...................................................10.9

10.7 Propelling liquid drain ............................................................................10.10

10.7.1 Environment instructions....................................................................................... 10.10

10.7.2 Propelling liquid drain preparation......................................................................... 10.10

10.7.3 Propelling liquid drain procedure........................................................................... 10.10

10.8 Propelling liquid system.........................................................................10.13

10.8.1 Environment instructions....................................................................................... 10.13

10.8.2 (Dis)assemble the discharge filter of the propelling liquid system........................ 10.13

10.8.3 Disassemble the suction filter at the propelling liquid tank ................................... 10.13

10.8.4 Assemble the suction filter at the propelling liquid tank........................................ 10.14

10.8.5 Replace the propelling liquid and the filters .......................................................... 10.14

10.8.6 Replace the venting filter at the propelling liquid system...................................... 10.14

10.8.7 2/2 way valves: inspection and preservation ........................................................ 10.15

10.9 Gearbox maintenance.............................................................................10.16

10.9.1 Oil change.............................................................................................................. 10.16

10.9.2 Grease the bearings and labyrinth seals .............................................................. 10.16

10.9.3 Cooling................................................................................................................... 10.16

10.9.4 Air filter................................................................................................................... 10.16

Contents

201150-IOM-EN-R03 2.5

10.10 Valves, angular model, in the discharge line .......................................10.17

10.10.1 Valve housing cover .............................................................................................. 10.17

10.10.2 Conical valve ......................................................................................................... 10.21

10.10.3 Valve seat .............................................................................................................. 10.22

10.10.4 Valve disk assembly.............................................................................................. 10.24

10.10.5 Valve guide bush ................................................................................................... 10.25

10.11 Valves, angular model, in the suction line............................................10.26

10.11.1 Valve housing cover .............................................................................................. 10.26

10.11.2 Conical valve ......................................................................................................... 10.28

10.11.3 Valve seat .............................................................................................................. 10.29

10.11.4 Valve disk, disassembly and assembly................................................................. 10.30

10.11.5 Valve guide bush, disassembly and assembly ..................................................... 10.30

10.12 Diaphragm housing unit.........................................................................10.31

10.12.1 Disassembly .......................................................................................................... 10.31

10.12.2 Cleaning after diaphragm leakage or damage or contamination ......................... 10.35

10.12.3 Assembly ............................................................................................................... 10.40

10.12.4 De-aerating the propelling liquid chamber ............................................................ 10.47

10.13 Piston unit ................................................................................................10.48

10.13.1 Disassembly .......................................................................................................... 10.48

10.13.2 Replace procedure for the dust cover rings.......................................................... 10.50

10.13.3 Assembly ............................................................................................................... 10.51

10.14 Pulsation dampener................................................................................10.53

10.14.1 Safety instructions ................................................................................................. 10.53

10.14.2 Remove the diaphragm......................................................................................... 10.54

10.14.3 Assemble the diaphragm....................................................................................... 10.55

10.14.4 Assemble the cover............................................................................................... 10.60

10.15 Nitrogen filling device.............................................................................10.60

11 Appendix: Parts - Lists and drawings (pump section)....... 11.1

11.1 Safety instructions for parts ....................................................................11.1

11.2 Ordering parts............................................................................................11.1

11.3 General the handling and storage conditions........................................11.1

11.3.1 Refer to the handling and storage instructions with the packing ............................ 11.1

11.3.2 General instructions................................................................................................. 11.1

11.3.3 Storage of synthetic materials ................................................................................. 11.1

11.4 Part List and drawings..............................................................................11.3

12 Appendix: Parts - Lists and drawings (special tools)......... 12.1

12.1 Safety instructions for parts ....................................................................12.1

12.2 Ordering parts............................................................................................12.1

12.3 Special tools ..............................................................................................12.3

13 Appendix: Electrical information .......................................... 13.1

14 Appendix: Catalogue information......................................... 14.1


SAFETY

201150-IOM-EN-R03 3.1

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3 SAFETY Pos: 8.2 /GEHO/Heading/H2/#.# Safety symbols @ 0\mod_1133271418089_31.doc @ 211 @

3.1 Safety symbols Pos: 8.3 /GEHO/Safety/Product Safety Pump/Safety Symbols Overview @ 0\mod_1133426149167_31.doc @ 242 @

The hazards are classified into various stages.

The table below gives a summary of the signs, classes of risk and signal words used in this manual.

Sign Signal word Definition Consequences

DANGER Dangerous situation Death or most serious injuries

WARNING Possible dangerous situation Death or most serious injuries

CAUTION Less dangerous situation Slight or minor injuries

Attention Possible harmful Possible damage to:

• The equipment

• The environment

Note or Information

Note for application hints and other useful information

No signal word indicating a dangerous or harmful situation

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SAFETY

3.2 201150-IOM-EN-R03

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3.2 Important information Pos: 8.6 /GEHO/Safety/General/Important information @ 0\mod_1137680237357_31.doc @ 1362 @

This manual is intended to help you operate this machine safely and effectively. It is intended for use by people who have followed the training program that this manual accompanies. If you have not followed this program, but would like to do so, then contact your supervisor or training manager. This machine was designed with safety in mind, and includes features to help prevent injury and damage. However, all powerful machines can be dangerous, if misused. This manual is intended to help you operate the machine in a safe manner. In this manual, the user is the body with authority over and responsibility for the machine (usually a company or a corporation). An operator is a person who physically interacts with the machine and/or the machine's control systems under the direction and with the consent of the machine's user. It is your responsibility to operate this machine in accordance with all the safety instructions and procedures in this manual, and with all other safety procedures in your workplace. It is the user's responsibility to make sure that the machine is correctly installed, configured, commissioned, operated, serviced and maintained and that such actions are only carried out by people who have been fully and properly trained for those tasks. It is also the user's responsibility to make sure that the machine is only used in full accordance with laws (and regulations, which have the force of law) in the jurisdiction in which the machine is installed.

DANGER

• Before attempting to use the machine, read, understand and know all the safety information

in this chapter.

• Pay particular attention to all warnings and cautions throughout this manual. If you do not follow all the warnings and procedures in this manual, then this could lead to serious injury to yourself or others, including death.

• If there is any safety instruction or procedure that you do not understand, then do not use the machine.

• Contact your supervisor and arrange proper training on the use of the machine.

• Use of the machine without understanding and following all the safety instructions and procedures in this manual could lead to serious injury to yourself or others, including death.

WARNING

• Never use the machine, until you are sure that the routine checks described is completed

and that the routine preventive maintenance program is up-to-date.

• If any part of the machine is known (or suspected) to be defective or wrongly adjusted, then do not use the machine until a repair has been made. Operation of the machine with defective or wrongly adjusted components could create safety hazards. This could lead to fatal or other serious personal injury.

WARNING

• Never use the machine until you have received adequate and proper training in its safe and

effective use.

• If you are unsure of your ability to use the machine safely and effectively, then do not do so. The use of the machine without proper and adequate training could lead to fatal or other serious personal injury.

• Never attempt to remove, modify, over-ride or frustrate any safety device on the machine. Interfering with safety devices could lead to fatal or other serious personal injury.

Pos: 8.7 /GEHO/Heading/H2/#.# Efficient use @ 0\mod_1133271247864_31.doc @ 207 @

SAFETY

201150-IOM-EN-R03 3.3

3.3 Efficient use Pos: 8.8 /GEHO/Safety/Product Safety Pump/Efficient use @ 0\mod_1133427598361_31.doc @ 248 @

• Apply correct and regular maintenance, according to these manual instructions.

• Always use genuine GEHO spare parts and wear parts. Pos: 8.9 /GEHO/Heading/H2/#.# Intended use @ 0\mod_1138263061409_31.doc @ 1911 @

3.4 Intended use Pos: 8.10 /GEHO/Safety/Product Safety Pump/Intended use-pump @ 0\mod_1138263117509_31.doc @ 1914 @

This pump (and/or the pump system components) is intended to pump a liquid media only. The liquid media is specified by the customer.

Refer to the chapter “Technical data” for a detailed specification. Pos: 8.11 /GEHO/Heading/H2/#.# General safety instructions @ 0\mod_1133271158987_31.doc @ 206 @

3.5 General safety instructions Pos: 8.12 /GEHO/Safety/Product Safety Pump/General safety instructions @ 0\mod_1133426798361_31.doc @ 244 @

DANGER

1 Always obey local legislation and local safety regulations and instructions. 2 Never cause a potentially dangerous situation. 3 Never touch moving parts. 4 Never loosen parts under pressure. 5 Never touch parts with high temperature. 6 Never touch parts under electrical power. 7 Never touch parts which contain dangerous or poisonous media.

Pos: 8.13 /GEHO/Heading/H2/#.# Qualified workers @ 0\mod_1133271087294_31.doc @ 203 @

3.6 Qualified workers Pos: 8.14 /GEHO/Safety/Product Safety Pump/Qualified workers @ 0\mod_1133271624877_31.doc @ 219 @

• Only personnel who have been given permission are allowed to work with or on the machine. • All personnel must only carry out the work they have been trained to perform.

This applies to both maintenance work and the normal machine operation. • All personnel working with or on the machine must have free access to the applicable manuals. • The operators must be familiar with all situations that may occur so that they can act rapidly and

effectively in the event of emergencies. Pos: 8.15 /GEHO/Heading/H2/#.# Safe working on the pump @ 0\mod_1133271313769_31.doc @ 209 @ 2

3.7 Safe working on the pump Pos: 8.16 /GEHO/Safety/Product Safety Pump/Working on the machinery @ 0\mod_1133428079834_31.doc @ 250 @ 5

• Make sure to be aware of all related safety warnings and instructions and procedures.

• Make sure to be aware of all other parts of the equipment, which are related and involved in securing the working zone and the equipment.

• Always use personal protective equipment during assembly and disassembly work on the pump.

General working instructions

• Before starting works on the machinery, switch off the involved power supply of that part of the machinery and secure the equipment against switching on.

• Never loosen any parts that contain pressure or hot or dangerous fluids or gasses.

• Never loosen any parts that are still under mechanical stress. Pos: 8.17 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

SAFETY

3.4 201150-IOM-EN-R03

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3.8 Safety equipment Pos: 8.19 /GEHO/Safety/Product Safety Pump/### Safety related documentation @ 4\mod_1215006153706_31.doc @ 36725 @ 3

3.8.1 Safety related documentation

DANGER

If applicable, then refer to the book "MANUFACTURING DATA RECORDS" ("MDR") of this pump for the documentation about CE conformity (as defined by the European "Directive on machinery 98/37/EC and 2006/42/EC") and other required safety related documentation.

Pos: 8.20 /GEHO/Safety/Product Safety Pump/### DANGER: CE conformity @ 4\mod_1214979575442_31.doc @ 36701 @ 3

3.8.2 CE conformity

DANGER

If failing to install and maintain the SAFETY EQUIPMENT in accordance with this manual, then the installation is no longer in CE-conformity (as defined by the European "Directive on machinery 98/37/EC and 2006/42/EC") and thus results in:

"... machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive ..."

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3.8.3 "EMERGENCY STOP" button Pos: 8.22 /GEHO/Safety/Product Safety Pump/DANGER: emergency button @ 4\mod_1214979911686_31.doc @ 36709 @ 5

CE conformity

DANGER

If failing to install and maintain the "EMERGENCY STOP" button equipment in accordance with this manual, then the installation is no longer in CE-conformity (as defined by the European "Directive on machinery 98/37/EC and 2006/42/EC") and thus results in:


Pos: 8.23 /GEHO/Safety/Product Safety Pump/Emergency stop button @ 0\mod_1137483963358_31.doc @ 1243 @ 555

Functional requirements

Refer for the "Emergency stop" procedure to the document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical data".

Operation and procedure

Refer to chapter "Start and Stop procedure" for details about the use of the "EMERGENCY STOP" button.

Safety and legal requirements

An emergency stop button must be provided, according to the CE regulations and according to the local regulations. The customer must assure this.

It is mandatory to install at least one "EMERGENCY STOP" button, within a short distance of the pump / machinery / equipment / components / installation. The installation of the "EMERGENCY STOP" system is not within the scope of the contract between the customer and Weir Minerals Netherlands. Responsible for the installation of the "EMERGENCY STOP" button is the customer, as stated in the written contract.

SAFETY

201150-IOM-EN-R03 3.5

INFORMATION

• An emergency stop situation is defined in the EN 60204 standard.

• An emergency stop is a human action in case of emergency, which is determined to stop a process or movement that could cause an unsafe situation.

• An emergency stop has priority towards all functions and controls in all kind of modes.

• Reset an emergency stop may not cause an automatic restart.

• Functional aspects for ‘switching off at emergency’ as described in the international document IEC 60364 or NEC should be observed.

• The final customer emergency stop design must be in accordance to the concerning risk class and all local regulations.

• If no MCC (motor control center) hardware is in the manufacturer’s scope of supply, then an emergency stop will not be added, due to lack of MCC configuration information.

Pos: 8.24 /GEHO/Heading/H3/#.#.# Safety covers and safety guards @ 0\mod_1137486661628_31.doc @ 1247 @ 3

3.8.4 Safety covers and safety guards Pos: 8.25 /GEHO/Safety/Product Safety Pump/Safety covers and safety guards #installed @ 0\mod_1137486711069_31.doc @ 1249 @

The equipment has safety covers and safety guards at all potential unsafe parts.

• Safety covers and safety guards must remain in place during operation.

• Safety covers and safety guards may only be removed by qualified personnel for maintenance or service work.


Technical data

201150-IOM-EN-R03 4.1

Pos: 10 /GEHO/Heading/H1/#. Technical data @ 0\mod_1133269719867_31.doc @ 179 @

4 Technical data Pos: 11.1 /GEHO/Heading/H2/#.# Manufacturer information @ 0\mod_1133443515208_31.doc @ 288 @

4.1 Manufacturer information Pos: 11.2 /GEHO/Technical data sheets/Project information-EN @ 0\mod_1133439392901_31.doc @ 273 @

WEIR Project information

WEIR Project name CBA

WEIR Project number 201150

Customer purchase order number 20 B/112 (LOI 18/0313/07-IMP)

Pos: 11.3 /GEHO/Heading/H2/#.# Customer information @ 0\mod_1133443655420_31.doc @ 291 @

4.2 Customer information Pos: 11.4 /GEHO/Technical data sheets/Project/201150/Customer information @ 6\mod_1233071196011_31.doc @ 46057 @ O

Customer information

Name CBA Companhia Brasileira de Aluminio, Brazil

Purchaser address/bills Companhia Brasileira de Aluminio Praça Ramos de Azevedo, 254-3°Andar 01037-912 São Paulo S.P. Brazil

Pos: 11.5 /GEHO/Heading/H2/#.# Manufacturer information @ 0\mod_1133443515208_31.doc @ 288 @

4.3 Manufacturer information Pos: 11.6 /GEHO/Technical data sheets/Manufacturer information EN @ 0\mod_1133272928581_31.doc @ 221 @

Manufacturer information

Name Weir Minerals Netherlands b.v.

Address P.O. Box 249 NL5900AE - VENLO, the Netherlands

Phone (+31) 77-3895200

Fax (+31) 77-3824844

E-mail [email protected]

Website, internet http://www.weirminerals.com

Department Installation, Commissioning

Phone (+31) 77-3895141

Fax (+31) 77-3824844: V. van der Koelen

Department Spare Parts

Phone (+31) 77-3895236

Fax (+31) 77-3824844: R. Reijnders Pos: 11.7 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

mailto:[email protected]

Technical data

4.2 201150-IOM-EN-R03

Pos: 11.8 /GEHO/Heading/H2/#.# Technical data @ 0\mod_1133270813820_31.doc @ 198 @

4.4 Technical data Pos: 11.9 /GEHO/Heading/H3/#.#.# Operating characteristics @ 0\mod_1133443294151_31.doc @ 286 @

4.4.1 Operating characteristics Pos: 11.10 /GEHO/Technical data sheets/Project/201150/Operation characteristics @ 6\mod_1233071217444_31.doc @ 46078 @

Operation characteristics

Side Companhia Brasileira de Aluminio Brazil

Location of the equipment under roof

Site elevation < 1000 masl (meters above sea level)

Ambient temperature, minimum +5°C

Ambient temperature, maximum +45°C

Atmosphere dust

Liquid to be pumped Slurry, Red Mud

Slurry temperature, minimum +5°C

Slurry temperature, maximum +60°C

Viscosity maximum 120 cP/mPas

Specific slurry gravity 1.5 until 3.0 [-]

Specific solid gravity 2.7 [-]

Solid concentration normal 47% maximum 50%

Maximum solid diameter < 3 mm

Miller number 49


Technical data

201150-IOM-EN-R03 4.3

Pos: 11.12 /GEHO/Heading/H3/#.#.# Pump and project data and identification @ 0\mod_1133444066872_31.doc @ 292 @ 3

4.4.2 Pump and project data and identification Pos: 11.13 /GEHO/Technical data sheets/Project/201150/GEHO PUMPS data 201150 @ 6\mod_1233071276624_31.doc @ 46098 @

Refer for the allowed operating performance and conditions to the GEHO pump identification plate.

P.O.Box 249 5900AE Venlo-Holland

Type TZPM 2000

Q(m3/h) 31 - 310 Proj. 814.201150

p (kPa) 16 000 Date 2011

n (s/min) 5.3 - 53.3 No. 7201150/1-2

P (kW) 144 - 1435

Legend

Q(m3/h) Capacity, minimum - maximum

p (kPa) Operating discharge pressure, maximum

n (s/min) Stroke rate per minute, minimum - maximum = spm = stroke cycles per minute of one piston = revolutions of the crankshaft.

Configuration data

Operating suction pressure Maximum 600 kPa Minimum = NPSH required 223 kPa- abs. Minimum alarm: refer to the SETPOINT of the pressure transmitter at the suction air vessel, as listed in document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST".

Pump power end ratio Direct driven

Piston stroke 508.0 mm

Piston diameter 300 mm

Pump diaphragm size 47.5 liter

Valve size, suction and discharge side API 12

Discharge pulsation dampener 2 x 150/160 (liter/bar) bladder type pre-charged dampener Refer for the allowed operation data to the type plate of this part.

Suction pulsation dampener 1 x suction air vessel, uncontrolled level Refer for the allowed operation data to the type plate of this part.

Technical data

4.4 201150-IOM-EN-R03

Refer for details also to:

- Document 814.201150.00 "DIMENSIONED OUTLINE DRAWING" in chapter "Instruments and drawings".

- Document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST "in chapter "Instruments and drawings".

- Document 814.201150.03 "P&I DIAGRAM TPZM 2000" in chapter "Instruments and drawings".

- Chapter "Electrical information".

- Chapter "Catalogue information". Pos: 11.14 /GEHO/Heading/H4/Connection - Electrical @ 0\mod_1133446672849_31.doc @ 306 @

4.4.2.1 Electrical connection Pos: 11.15 /GEHO/Technical data sheets/Voltage/Brasil 6600/60/3-4000/60/3 - 440/60/3 - 220/60/1-24Vdc @ 6\mod_1233315609403_31.doc @ 46352 @

Item Voltage [V] Frequency [Hz] Phases

Transformer 6600 60 3

Main drive motor 4000 60 3

Auxiliary motors 440 60 3

Control panel 220 60 1

Control volts 24 dc 1 Pos: 11.16 /GEHO/Heading/H4/Pump drive @ 0\mod_1133448795551_31.doc @ 321 @

4.4.2.2 Pump drive Pos: 11.17 /GEHO/Technical data sheets/Main E-motor/ABB - AMA 500 L6L BAFTH#201150 @ 6\mod_1233316075505_31.doc @ 46362 @

Main E-motor

Refer also to document 814.201150.30 in chapter "Catalogue information", Drive unit", 'Electric motor" and to document 2814.201150.00 = "DIMENSIONED OUTLINE DRAWING" and to the data given at the motor rating plate.

Manufacturer ABB

Type / size AMA 500 L6L BAFTH

Voltage 4000 V – 60 Hz – 3 Phases

Speed range 117,8 - 1182.1 rpm

Power range 155 - 1549 kW

Protection class enclosure IP56

Duty S1

Insulation class F

Cooling system Cooling water Refer to the document 2814.201150.19 = "UTILITY CONSUMPTION LIST".

Technical data

201150-IOM-EN-R03 4.5

Pos: 11.18 /GEHO/Technical data sheets/Frequency converter/ABB - ACS 1014-W1-P5-00-SH03 @ 6\mod_1233317612547_31.doc @ 46372 @

Frequency converter

Refer also to document 2814.201150.38 in chapter "Catalogue information" and to document 2814.201150.00 "DIMENSIONED OUTLINE DRAWING" and the data given at the type plate of this part.

Manufacturer ABB

Type ACS 1014-W1-P5-00-SH03

Voltage 440V – 60 Hz – 3 Phases

Protection class enclosure IP31

Cooling system Water cooling Refer to the document 2814.201150.19 = "UTILITY CONSUMPTION LIST".

Pos: 11.19 /GEHO/Technical data sheets/Transformer/ABB CTMP 7 HC2100#201150 @ 6\mod_1233320406708_31.doc @ 46385 @

Transformer


Manufacturer ABB

Type CTMP 7 HC2100, ONAN

Protection class enclosure IP56, oil filled

Primary voltage 6600V – 60 Hz – 3 phases

Primary power 2 x 1050 kVA

Secondary voltage 2 x 2305V – 60 Hz – 3 phases

Pos: 11.20 /GEHO/Technical data sheets/Gearbox/Hansen - QHPQ2-TRN-25#201150 @ 6\mod_1233321211257_31.doc @ 46392 @

Gearbox


Manufacturer Hansen

Type QHPQ2-TRN-25

Gearbox ratio 22.177

Gear cooling Cooling water Refer to the document 2814.201150.19 = "UTILITY CONSUMPTION LIST".

Pos: 11.21 /GEHO/Heading/H4/Shaft coupling @ 0\mod_1133540284412_31.doc @ 341 @

Technical data

4.6 201150-IOM-EN-R03

4.4.2.3 Shaft couplings Pos: 11.22 /GEHO/Technical data sheets/Shaft coupling/Flender - RUPEX RWN 500 @ 3\mod_1201861359897_31.doc @ 26005 @

E-motor / Gearbox Refer to chapter "Catalogue information" for details.

Manufacturer Flender

Type RUPEX RWN 500

Pos: 11.23 /GEHO/Technical data sheets/Shaft coupling/Flender - ZAPEX ZWN 690A @ 6\mod_1233321541439_31.doc @ 46403 @

Pump shaft / Gearbox Refer to chapter "Catalogue information" for details.

Manufacturer Flender

Type ZAPEX ZWN 690A


Technical data

201150-IOM-EN-R03 4.7

Pos: 11.25 /GEHO/Heading/H2/#.# Tightening torques @ 0\mod_1133269909891_31.doc @ 183 @

4.5 Tightening torques Pos: 11.26.1 /GEHO/Heading/H3/#.#.# General instructions @ 7\mod_1248334427435_31.doc @ 52981 @

4.5.1 General instructions Pos: 11.26.2 /GEHO/Technical data sheets/General torques/Clean and grease all @ 7\mod_1248334260103_31.doc @ 52990 @

Before assembly of a threaded connection: • Clean and grease all the threaded sections with a suitable grease. This accomplishes: • Proper tightening a prescribed tightening torque. • Easy assembly and disassembly. • Preventing corrosion of the threaded sections. Pos: 11.26.3 /GEHO/Heading/H3/#.#.# General torques @ 0\mod_1133270125801_31.doc @ 190 @

4.5.2 General torques Pos: 11.26.4 /GEHO/Technical data sheets/General torques/General torques R03 grade 8.8 + 10.9 Nm @ 10\mod_1286972418734_31.doc @ 72393 @

Size Torque [Nm]

property classes, grade 8.8

Torque [Nm]

property classes, grade 10.9

M8 20 25

M10 40 55

M12 70 95

M16 165 230

M20 320 455

M24 550 785

M27 810 1140

M30 1120 1565

M33 1505 2120

M36 1930 2710

M39 2490 3500

M42 3090 4345

M45 3870 5445

M48 4700 6610

M52 6050 8510

Pos: 11.27.1 /GEHO/Heading/H3/#.#.# Foundation bolt torques according to DIN 529 @ 0\mod_1133863490701_31.doc @ 397 @ 3

4.5.3 Foundation bolt torques according to DIN 529 Pos: 11.27.2 /GEHO/Technical data sheets/General torques/Foundation bolt torques - grade 4.6 Nm @ 10\mod_1286973259140_31.doc @ 72415 @

General = grade 4.6

Size Torque [Nm] Size Torque [Nm]

M20 120 M33 565

M24 210 M36 725

M27 305 M39 935

M30 420 M42 1160 Pos: 11.28 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Technical data

4.8 201150-IOM-EN-R03

Pos: 11.29 /GEHO/Heading/H3/#.#.# Special torques @ 0\mod_1133270014401_31.doc @ 187 @

4.5.4 Special torques Pos: 11.30 /GEHO/Technical data sheets/Special torques/ATTENTION: A-number reference @ 12\mod_1303286056265_31.doc @ 85382 @

ATTENTION

A-numbers mentioned below, have no further application in this manual. They are required to trace the data in our safety & quality assurance procedure. If you have questions about the instructions below, then please refer to that specific A-number. (For the part-numbers and drawing-numbers are used in various configurations.)

Pos: 11.31 /GEHO/Technical data sheets/Special torques/INFO - Position numbers @ 1\mod_1166014236919_31.doc @ 9320 @

INFORMATION

Position numbers specified in the list must be ignored, if they are not listed in the corresponding parts list.

Pos: 11.32 /GEHO/Technical data sheets/Special torques/Special tools/897.010.710-hydr.pump DRAWING T.897.000.318 @ 2\mod_1192106525746_31.doc @ 18272 @

Special tool: "HYDRAULIC PUMP UNIT" = 897.010.710, drawing T.897.000.318 Pos: 11.33 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.622 Hydr.pump-imp 200 MPA @ 0\mod_1143217678540_31.doc @ 2882 @

A.807.004.622 Part list ID Torque Pressure

Adapter / connecting nipple 002 / 003 50 Nm 37 LB-FT

Hydraulic unit, with hose 002 / 003 maximum 200 000 kPa 2 000 bar 29 000 psig

WARNING: NEVER pressurize the pump, if it is not connected with the hose to a tool. For this can damage the sealing ring at the quick release connectors ("nipples").

002 / 004 Non

Pos: 11.34 /GEHO/Heading/H5/H5 Discharge line @ 4\mod_1213287464731_31.doc @ 33137 @ 5

Discharge line Pos: 11.35 /GEHO/Technical data sheets/Special torques/Suction valve unit/H.831.020.378, drawing T.831.000.472 discharge @ 5\mod_1231253291524_31.doc @ 45032 @

Discharge "VALVE UNIT" = 831.020.378, drawing T.831.000.472 Pos: 11.36 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.005.008 - Discharge hydr+trekstang-nut24=tight @ 5\mod_1226320766581_31.doc @ 40345 @

A.807.005.008 - Discharge valve Part list ID Torque [Nm] Pressure kPa Rev.

Valve ring lock nut 013 / 010 / 011 300

Connecting nipple / adapter 026 / 027 50

Assembly connecting nipple + adapter / valve housing + valve cover

{026/027} / 001 + 003

50

Nuts / discharge line 051 / 050 1100

Disassembly: valve cover removal procedure 003 R02

Housing nuts for the fixation of the valve housing, to keep the housing in place during removal of the cover.

1 Tighten all the nuts down to the valve housing.

024 Hand tight, use the pin.

2 Pressurize the pistons (018) with the hydraulic pump.

018 110 000

3 Valve cover lock nut 019 Loosen the nuts, effort about 200-400 Nm

4 Depressurize the hydraulic pump. 0

Technical data

201150-IOM-EN-R03 4.9

A.807.005.008 - Discharge valve Part list ID Torque [Nm] Pressure kPa Rev.

5 Strain nut 020 Loosen the nuts

Assembly: valve cover tightening procedure 003 R02

1 Tighten the strain-nut 020 200

2 Pressurize the pistons (018) with the hydraulic pump.

110 000

3 Final-tighten the locknuts. 019 200-400

4 Depressurize the hydraulic pump. 0

Housing nuts for the fixation of the valve housing.After de-pressurizing:

5 Tighten all the nuts down to the valve housing.

024 Hand tight, use the pin.

Pos: 11.37 /GEHO/Heading/H5/H5 Suction line @ 4\mod_1213287469058_31.doc @ 33145 @ 5

Suction line Pos: 11.38 /GEHO/Technical data sheets/Special torques/Suction valve unit/H.831.020.379, drawing T.831.000.441 suction @ 5\mod_1227107014546_31.doc @ 43993 @

Suction "VALVE UNIT" = 831.020.379, drawing T.831.000.441 Pos: 11.39 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.005.009 - Suction hydr. @ 5\mod_1227107122215_31.doc @ 44003 @

A.807.005.009 - Suction valve Part list ID Torque [Nm] Pressure [kPa]

Valve ring lock nut 013 300

Valve cover nut 019 200 - 400 110 000

Nut valve housing / Discharge line 051 2200

Adapter / Connecting nipple 027 / 026 50

Assembly adapter and nipple / Valve housing (027,026) / 001 50


Technical data

4.10 201150-IOM-EN-R03

Pos: 11.41 /GEHO/Technical data sheets/Special torques/Diaphragm housing unit/H.832.010.279, drawing T.832.000.250 @ 5\mod_1227107554999_31.doc @ 44015 @

"DIAPHRAGM HOUSING UNIT" - 832.010.279, drawing T.832.000.250 Pos: 11.42 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.005.018+A.807.004.805 Diaphragm housing+unit-hydr. @ 6\mod_1233565757271_31.doc @ 46414 @

A.807.005.018 Part list ID Torque [Nm] Pressure [kPa]

Monitoring rod / diaphragm 015 / 019 140 Use "LOCTITE NUTLOCK 243"

Nut M39 / corner + middle piece connection 040 / 039 2000

Nut M39 / frame connection 043 / 042 3000 Re-tensioning is not required. In case of doubt, first contact and consult our WEIR-GEHO service department.

Nut M52 / stud bolt 046 / 038 5200

Capscrews for locking the clamping bush in the diaphragm housing

063 / 0016 / 003 Use "LOCTITE NUTLOCK 243"

Capscrews 081/004+005+006 295 Re-tensioning is not required. In case of doubt, first contact and consult our WEIR-GEHO service department.


Use the special tool: Hydr. diaphr. cover mounting T.897.000.296

Use pin ID 013 Use hydraulic pump

Diaphragm housing cover nut 045

1. Tighten

1.1. Pre-tighten 045 Pre-tighten cover nut with pin, tight by hand.

140 000 kPa 20 300 psig

1.2. Relieve for settling of parts Relieve oil pressure.

1.3. Final-tighten 045 Final-tighten cover nut with pin, tight by hand.

140 000 kPa 20 300 psig

2. Loosening 045 Loosening cover nut with pin by hand.

140 000 kPa 20 300 psig


Technical data

201150-IOM-EN-R03 4.11

Pos: 11.44 /GEHO/Technical data sheets/Special torques/Piston unit/H.835.0990.169, drawing T.835.000.190 @ 4\mod_1215432684223_31.doc @ 36754 @

"PISTON UNIT" - 835.0990.169, drawing T.835.000.190 Pos: 11.45 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.974-r01 Piston unit @ 6\mod_1233566553005_31.doc @ 46422 @

A.807.004.974-R01 "PISTON UNIT" Part list ID Torque [Nm] Pressure [kPa]

Piston unit lock nut 006 840

Piston body lock nut 010 1000 Use "LOCTITE 243"

Bolt 011 Use "LOCTITE 2701"

Pos: 11.46 /GEHO/Heading/H5/H5 Discharge line @ 4\mod_1213287464731_31.doc @ 33137 @ 5

Discharge line Pos: 11.47 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/H.851.010.110, drawing T.851.000.336 @ 2\mod_1193906054150_31.doc @ 19004 @

"PULSATION DAMPER UNIT" 150/160 = 851.010.110, drawing T.851.000.336 Pos: 11.48 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.667-851.010.110=150/160 puls.damp. @ 1\mod_1160476787525_31.doc @ 6422 @


Valve, if applicable 007 Use "LOCTITE NUTLOCK 542".

Pulsation damper flange screw 013 2800

Pulsation damper cover nut 014 2800


Technical data

4.12 201150-IOM-EN-R03

Pos: 11.50 /GEHO/Heading/H2/#.# Auxiliary connections and Lubrication data @ 0\mod_1137667733207_31.doc @ 1351 @

4.6 Auxiliary connections and lubrication data Pos: 11.51 /GEHO/Technical data sheets/Refer to Utility consumption list @ 0\mod_1148974052988_31.doc @ 4381 @

Refer to the document “UTILITY CONSUMPTION LIST” for more information about auxiliary connections and lubrication data.

Pos: 11.52 /GEHO/General/Attention, Warning and Note/Information - Check lubricant @ 0\mod_1143532829375_31.doc @ 2934 @

INFORMATION

Depending on the oil condition the changing intervals can differ substantially.

• Check the oil regularly for contamination and chemical properties by an authorized laboratory.

• Always keep reserve oil in stock.

Pos: 11.53 /GEHO/Heading/H2/#.# Drawings+Lists+Instruments @ 0\mod_1133876951146_31.doc @ 421 @ 2

4.7 Drawings + lists + instruments

Pos: 11.54 /GEHO/Technical data sheets/Project/201150/Instrument and drawings @ 6\mod_1233071207730_31.doc @ 46068 @

Drawings and lists

814.201150.00 "DIMENSIONED OUTLINE DRAWING"

814.201150.01 "FOUNDATION DRAWING"

814.201150.02 "INSTRUMENT AND EQUIPMENT LIST"

814.201150.03 "P & I DIAGRAM"

814.200000.04 "FLUSHING/FILLING/DRAIN CONNECTIONS"

V.814.201150.15 "PACKING"

814.201150.19 "UTILITY CONSUMPTION LIST"

814.201150.20 "DESCRIPTION OF PUMP CONTROL SYSTEM"

814.200000.22 "TYPICAL MANUAL OF THE GEHO TOUCH PANEL TZPM"

MI.093701 "INSTRUCTION FOR LUBRICATION OIL MONITORING & SAMPLING"

STO.201150 "STORAGE REQUIREMENTS"


Description

201150-IOM-EN-R03 5.1

Pos: 13.1 /GEHO/Heading/H1/#. Description @ 0\mod_1134483846926_31.doc @ 448 @ 1

5 Description Pos: 13.2.1 /GEHO/Heading/H2/#.# Introduction @ 0\mod_1144834888602_31.doc @ 3092 @

5.1 Introduction Pos: 13.2.2 /GEHO/Description/Introduction/Media @ 0\mod_1134634042426_31.doc @ 544 @

The GEHO piston diaphragm pump is a reciprocating, positive displacement pump, designed to handle liquids contaminated with solids, like sludge’s, slurry and mud, particularly where abrasive or aggressive materials are involved. Pos: 13.2.3 /GEHO/Description/Introduction/Diaphragm unit @ 0\mod_1134633771977_31.doc @ 542 @

A rubber diaphragm separates the pumped liquid from the clean propelling liquid. The pumped liquid has no contact with moving parts, such as the piston, the piston rod or the cylinder liner.

This enables to use low-wear components to pump at high pressure a solids containing liquid or slurry.

Pos: 13.2.4 /GEHO/Description/Introduction/Wearing and replacement parts @ 0\mod_1134635894018_31.doc @ 574 @

The wearing parts and replacement parts are easily accessible for inspection and repair. Pos: 13.2.5 /GEHO/Heading/H4/Wearing parts @ 0\mod_1134635462418_31.doc @ 560 @

5.1.1.1 Wearing parts Pos: 13.2.6 /GEHO/Description/Introduction/Wearing parts: Definition @ 0\mod_1134639095462_31.doc @ 580 @

Wearing parts are parts subject to exchange regularly. Pos: 13.2.7 /GEHO/Description/Introduction/Wearing parts: List @ 0\mod_1134635624621_31.doc @ 570 @

These are:

• Suction valve

• Discharge valve Pos: 13.2.8 /GEHO/Heading/H4/Replacement parts @ 0\mod_1134635502866_31.doc @ 564 @

5.1.1.2 Replacement parts Pos: 13.2.9 /GEHO/Description/Introduction/Replacement parts: Definition @ 0\mod_1134639331822_31.doc @ 582 @

Replacement parts are parts subject to be replaced, if required. Pos: 13.2.10 /GEHO/Description/Introduction/Replacement parts: List @ 0\mod_1134635786604_31.doc @ 572 @

These are:

• Pump diaphragm

• Pulsation dampener diaphragm Pos: 13.2.11 /GEHO/Heading/H4/Non-wearing parts @ 0\mod_1134635392998_31.doc @ 555 @

5.1.1.3 Non-wearing parts Pos: 13.2.12 /GEHO/Description/Introduction/TZPM/Non-wearing parts @ 0\mod_1134634939436_31.doc @ 554 @

• Piston

• Piston rod

• Piston seal rings

• Cylinder liner Pos: 13.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Description

5.2 201150-IOM-EN-R03

Pos: 13.4.1 /GEHO/Heading/H2/#.# Working principle @ 0\mod_1135000311087_31.doc @ 611 @

5.2 Working principle Pos: 13.4.2 /GEHO/Description/Working principle/TZPM/TZPM general @ 6\mod_1234867089317_31.doc @ 47582 @

5.2.1 Numbering of the diaphragm housings

1 2 3

1 2 3NUMBERPISTON+ CYLINDERLINER:

POWER END

Figure 5.1:

5.2.2 Typical flow of the GEHO TZPM pump

Each single acting piston moves the propelling liquid to drive the connected diaphragm, which then pumps the slurry.

With 1 revolution of the crankshaft, 3 pistons make in total 3 diaphragm suction strokes and 3 diaphragm discharge strokes.

The total pump flow is the combined flow from the 3 diaphragm housings.

The 3 pistons follow each other at 120° degree crankshaft angle, as represented in the figure.

Typical flow of TZPM pump

-200

-150

-100

-50

0

50

100

150

200

0 30 60 90 120 150 180 210 240 270 300 330 360

Crankshaft angle

Typic

alf

low

Q1 Q3 Q2

DISCHARGE FLOW = Q1 + Q2 + Q3

SUCTION FLOW = Q1 + Q2 + Q3

DISCHARGE 2SUCTION 2

DISCHARGE 3SUCTION 3 SUCTION 3

DISCHARGE

DISCHARGE 1 SUCTION 1

Figure 5.2: Typical flow of a GEHO TZPM pump

Pos: 13.4.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Description

201150-IOM-EN-R03 5.3

Pos: 13.4.4 /GEHO/Description/Working principle/TZPM/Suction stroke @ 0\mod_1134999056904_31.doc @ 606 @ 3

5.2.3 Suction stroke

The piston (A) moves backward and decompresses the propelling liquid (B).

The diaphragm (F) moves backward.

The resulting low pressure in the slurry chamber (E) forces • the discharge valve (G) to close, • the suction valve (C) to open.

The slurry fills the slurry chamber (E) of the diaphragm housing unit through the suction line (D).

AB

G

F

E

C

D

Figure 5.3: Working principle: Suction stroke

(The figure shows a general schematic arrangement, applicable for more versions.)

Pos: 13.4.5 /GEHO/Description/Working principle/TZPM/Discharge stroke @ 0\mod_1134999494473_31.doc @ 608 @ 3

5.2.4 Discharge stroke

The piston (A) moves forward and compresses the propelling liquid (B).

The diaphragm (F) moves forward.

The resulting high pressure in the slurry chamber (E) of the diaphragm housing unit forces • the suction valve (C) to close, • the discharge valve (G) to open.

The slurry leaves the slurry chamber (E) through the discharge line (H).

H

G

F

E

C

B A

Figure 5.4: Working principle: Discharge stroke



Description

5.4 201150-IOM-EN-R03

Pos: 13.6.1 /GEHO/Heading/H2/#.# Pump control system @ 0\mod_1134569924544_31.doc @ 510 @

5.3 Pump control system Pos: 13.6.2 /GEHO/Description/Pump control system/Pump control system @ 0\mod_1135075605523_31.doc @ 701 @

The pump control system monitors and controls the operation.

The pump control system includes:

• GEHO HMI PANEL (HMI = "Human Machine Interface").

• A PLC (Programmable Logic Controller).

The pump control system monitors the pump alarm and trip parameters. It also monitors the pump diaphragm position to prevent an overload of the diaphragm. The pump control system allows a local or remote pump start or pump stop procedure as well as the speed control.

For maintenance purpose the GEHO HMI+PLC allows the manual operation of the propelling liquid fill and outlet valves.

If required, then the pump parameters can also be made available to the customer control system.

Refer to chapter “Electrical information” for a detailed description of the pump control system. Pos: 13.7.1 /GEHO/Heading/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452 @

5.4 Drive unit Pos: 13.7.2 /GEHO/Description/Drive unit/Gearbox type @ 0\mod_1134639813244_31.doc @ 584 @

• The main electric motor and the gearbox are mounted on a one structure welded base frame.

• The mounting surfaces for these components are machined to allow optimum alignment.

• Anchoring holes in the bottom of the base frame are provided.

• The main electric motor shaft and the gearbox input shaft are connected with a flexible shaft coupling.

• The gearbox output shaft and the pump shaft are connected with a gear coupling.

• Coupling guards are provided for safety.

Pos: 13.8 /GEHO/Heading/H2/#.# Power end @ 0\mod_1134484023820_31.doc @ 454 @

5.5 Power end Pos: 13.9 /GEHO/Description/Power end/Introduction/Introduction @ 0\mod_1136371259991_31.doc @ 916 @

The power end converts the circular motion of the pump drive into a linear motion of the connecting rod and crosshead and piston. Pos: 13.10 /GEHO/Description/Power end/Project/TZPM 1600+2000=201065+++ @ 2\mod_1193911247051_31.doc @ 19015 @

The power end includes the following items:

• Cast power end with shaft seals and inspection covers to seal against exterior contamination.

• Direct driven crankshaft.

• Forged alloy steel crankshaft supported on self-aligning roller bearings.

• Heavy duty anti-friction bearings.

• Crossheads with replaceable guides.

• Crosshead extension/piston rods constructed in sections for simple replacement of the pistons.

• Integral pressurized lube oil system.

• Piston rod stuffing box to prevent lube oil contamination and leakage.

• A turning gear device for manually rotating the pump in an unloaded condition.

• Lock-out of the motor driver when the turning gear is engaged. Pos: 13.11.1 /GEHO/Heading/H3/#.#.# Lubrication unit @ 0\mod_1134568393543_31.doc @ 498 @

Description

201150-IOM-EN-R03 5.5

5.5.1 Lubrication unit Pos: 13.11.2 /GEHO/Description/Power end/Lubrication unit/TZPM/Lubrication methods @ 8\mod_1256563912308_31.doc @ 56021 @

Two lubrication methods are applied: 1 The Splash lubrication. 2 The force feed lubrication system. The Splash lubrication of the crankshaft bearings, affected by their own movement in the oil sump. The force feed lubrication system lubricate points that are difficult to reach by the splashed oil such as the bearings of the drive shaft and the crankshaft, the upper and lower side of the crosshead liners and the crosshead bearings.

CAUTION

The force feed lubrication system is a system that remains under pressure even after shut down the pump. Shut off the lubrication pump, before carrying out maintenance and repair activities.

Pos: 13.12 /GEHO/Heading/H2/#.# Liquid end @ 0\mod_1134568182139_31.doc @ 492 @

5.6 Liquid end Pos: 13.13.1 /GEHO/Description/Liquid end/Introduction/TZPM/Main items - TZPM - Header @ 0\mod_1145875032918_31.doc @ 3323 @

The GEHO TZPM pump consist of the following parts: Pos: 13.13.2 /GEHO/Description/Liquid end/Introduction/TZPM/Main items - TZPM @ 0\mod_1136360416839_31.doc @ 882 @

• 3 Piston units.

• 3 Diaphragm housing units.

• 3 Suction valve units.

• 1 Suction manifold.

• 3 Discharge valve units.

• 1 Discharge manifold. Pos: 13.13.3 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (2) @ 0\mod_1158588058198_31.doc @ 6154 @

• 2 Discharge pulsation dampeners. Pos: 13.13.4 /GEHO/Description/Liquid end/Introduction/Main items/Air vessel - Suction @ 0\mod_1145981103040_31.doc @ 3414 @

• 1 Suction air vessel. Pos: 13.13.5 /GEHO/Description/Liquid end/Introduction/Divisions @ 0\mod_1149662408190_31.doc @ 4417 @

The liquid end is divided by a rubber diaphragm into two mechanically separated sections:

• The propelling liquid section.

• The slurry section. Pos: 13.13.6 /GEHO/Description/Liquid end/Introduction/Propelling liquid section/TZPM @ 1\mod_1166113655949_31.doc @ 11322 @

5.6.1 The propelling liquid section

The propelling liquid section is filled with the propelling liquid.

The propelling liquid section consists of:

• The piston unit. • The rear side of the diaphragm housing unit. Pos: 13.13.7 /GEHO/Description/Liquid end/Introduction/Slurry section/Standard @ 0\mod_1149662677848_31.doc @ 4423 @

5.6.2 The slurry section

Only the slurry section has contact with the pumped liquid.

The slurry section consists of:

• The slurry front side of the diaphragm housing unit.

• The suction valve unit.

• The discharge valve unit. Pos: 13.13.8 /GEHO/Description/Liquid end/Introduction/Main items/Air vessel - Suction @ 0\mod_1145981103040_31.doc @ 3414 @

• 1 Suction air vessel. Pos: 13.13.9 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (2) @ 0\mod_1158588058198_31.doc @ 6154 @

• 2 Discharge pulsation dampeners. Pos: 13.14 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Description

5.6 201150-IOM-EN-R03

Pos: 13.15.1 /GEHO/Heading/H3/#.#.# Piston unit @ 0\mod_1134569925466_31.doc @ 512 @

5.6.3 Piston unit Pos: 13.15.2 /GEHO/Description/Liquid end/Piston unit/TZPM/Piston rod - Tapered @ 0\mod_1145878938338_31.doc @ 3329 @

The piston rod connects the piston and the crosshead rod. The tapered ends are connected by the rod clamping piece.

Pos: 13.15.3 /GEHO/Description/Liquid end/Piston unit/Piston @ 0\mod_1135242883584_31.doc @ 732 @

The piston is provided with 2 sets of piston seal rings (chevron roof shaped rings) and a piston guide ring.

The piston guide ring centers the piston in the cylinder liner. Pos: 13.15.4 /GEHO/Description/Liquid end/Piston unit/TZPM/Piston seal rings @ 0\mod_1135069059470_31.doc @ 661 @

The piston seal to the propelling section prevents loss of propelling liquid from the diaphragm housing. The piston seal ring to the air side prevents drawing in of air or drawing in of flushing liquid. Pos: 13.15.5 /GEHO/Description/Liquid end/Piston unit/TZPM/Cylinder liner @ 0\mod_1135069465694_31.doc @ 666 @

The cylinder liner is clamped into the diaphragm housing end by a thrust piece. Pos: 13.15.6 /GEHO/Description/Liquid end/Piston unit/Resistance and replacement @ 0\mod_1135070106045_31.doc @ 670 @

The cylinder liner is highly wear resistant. It is not damaged immediately, when as a result of diaphragm rupture the abrasive solids enter the propelling liquid section. The piston body and the cylinder liner can be changed quickly and easily.

Pos: 13.16.1 /GEHO/Heading/H3/#.#.# Flushing unit @ 0\mod_1136284703903_31.doc @ 806 @

5.6.4 Flushing unit Pos: 13.16.2 /GEHO/Description/Liquid end/Flushing unit/TZPM/Piston flushing unit @ 0\mod_1136369150107_31.doc @ 908 @

The piston flushing unit uses the propelling liquid to lubricate the piston and cylinder liner. Pos: 13.16.3 /GEHO/Description/Liquid end/Flushing unit/Flushing unit - Common @ 0\mod_1136369685006_31.doc @ 912 @

The propelling liquid for the flushing unit is supplied by the propelling liquid unit.

During normal operation the flushing unit is active. If propelling liquid needs to be supplied to the propelling liquid section, then the flow to the flushing unit will be switched off and will be used for the propelling liquid control unit. Logics in the PLC prevent that the absence of propelling liquid in the flushing unit will not exceed 1 minute. Pos: 13.17 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Description

201150-IOM-EN-R03 5.7

Pos: 13.18.1 /GEHO/Heading/H3/#.#.# Propelling liquid control system @ 0\mod_1134632211894_31.doc @ 522 @

5.6.5 Propelling liquid control system Pos: 13.18.2 /GEHO/Heading/H5/H5 References @ 10\mod_1288253105484_31.doc @ 72842 @ 5

References Pos: 13.18.3 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/Refer to "Start-up, priming procedure" @ 6\mod_1234953648836_31.doc @ 47661 @

NOTE

Refer to chapter "Start-up, priming procedure" for details about

• how to do a save initial start of the automatic system, after a drain of the propelling liquid.

Pos: 13.18.4 /GEHO/Description/Liquid end/Propelling liquid control system/Caution - Release remaining pressure @ 0\mod_1136282494105_31.doc @ 786 @

CAUTION

Before installation or service or maintenance work:

• Refer to the concerning chapters.

• Stop the auxiliary propelling liquid motor.

• Release the pressure from the propelling liquid control system.

The system remains under pressure even after shutting down the pump. The system is equipped with an accumulator. This accumulator is preloaded with pressurized nitrogen.

Pos: 13.18.5 /GEHO/Description/Liquid end/Propelling liquid control system/General functions prop.liquid TZPM+ZPM @ 10\mod_1288344581984_31.doc @ 72921 @ 4

5.6.5.1 General functions

The pump is standard equipped with the patented GEHO propelling liquid automatic control system. It provides during operation a full automatic control of the required quantity of propelling liquid between the piston and the diaphragm.

• It controls and limits the stroke of the pump diaphragms.

• It regulates the volume of the propelling liquid within limits.

• It protects the diaphragms against overstress.

If the normal diaphragm stroke position changes (as a result of increase or decrease of propelling liquid), then the position marker at the monitoring rod reaches the rear or front monitoring probe. Then the connected "PLC" ("PROGRAMMABLE LOGIC CONTROLLER") actuates a fill or a drain of propelling liquid.

The patented GEHO propelling liquid automatic control system prevents:

Possible causes:

Overstress of the diaphragm. Blow up the diaphragm.

Increase of propelling liquid volume.

Diaphragm may strike the rear wall of the diaphragm housing. Decrease of propelling liquid volume.

Possible causes for a (slow, long term) change of the propelling liquid volume in diaphragm housing:

• Liquid increase by flush liquid, wiped by the piston sealing rings from the cylinder liner.

• Liquid loss at the piston sealing rings from the high pressure chamber.

• Liquid loss at other seals.


Description

5.8 201150-IOM-EN-R03

Pos: 13.18.7 /GEHO/Heading/H4/#.#.#.# Overview @ 1\mod_1165494429019_31.doc @ 9072 @

5.6.5.2 Overview Pos: 13.18.8 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM schematics @ 0\mod_1135261173624_31.doc @ 755 @

AE BCDF

G

H

I

PLC

K

L

J4 FILLING 5 OUTLET

12

3

Figure 5.5: GEHO TZPM pump schematics


A Slurry suction line B Slurry chamber

C Propelling liquid D Suction valve

E Diaphragm F Piston

G Piston rod H Cylinder liner

I Monitoring rod with a position marker for limitation of the diaphragm stroke

J Discharge valve

K Slurry discharge line

L Monitoring probes for minimum and maximum stroke of the diaphragm (for limitation of the diaphragm stroke)

1 "AIR" = Compressed air supply connection

2 Propelling liquid automatic control system

3 "PLC" = "PROGRAMMABLE LOGIC CONTROLLER"

4 "FILLING" = automatic filling of propelling liquid, if the position marker (I) at the rod reaches the minimum-probe ZSL

5 "OUTLET" = automatic drain of propelling liquid, if the position marker (I) at the rod reaches the maximum-probe ZSH


Description

201150-IOM-EN-R03 5.9

Pos: 13.18.10 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM Propelling liquid control system R02 @ 2\mod_1175168658938_31.doc @ 12922 @ 455544544554

5.6.5.3 Working principle of the filling valves + outlet valves

FILLING PROBEOUTLET PROBE

3 4 5

ZSH ZSL

6 = PISTON

7 = HV FILLING VALVE

8 = HV OUTLET VALVE

1 2

Figure 5.6: Propelling liquid automatic control system

1 ZSH (switch high) monitoring probe for the outlet of propelling liquid 2 ZSL (switch low) monitoring probe for filling of propelling liquid 3 Diaphragm 4 Monitoring rod 5 Magnet to trigger the switches 6 Piston 7 HV = hydraulic valve for filling of propelling liquid.

HV1 = valve for filling diaphragm housing 1. HV2 = valve for filling diaphragm housing 2. HV3 = valve for filling diaphragm housing 3.

8 HV = hydraulic valve for outlet of propelling liquid. HV5 = valve for outlet diaphragm housing 1. HV6 = valve for outlet diaphragm housing 2. HV7 = valve for outlet diaphragm housing 3.

Normal pumping conditions

Under normal pumping conditions the magnet (5) in the diaphragm rod (4) moves between the monitoring probes (1) ZSH (switch high) and (2) ZSL (switch low), without actuating them.

Filling by the ZSL switch high

If there is too less propelling liquid in the propelling liquid chamber, then the magnet actuates monitoring probe ZSL (switch low), which gives an impulse to an input of the GEHO control box. Due to this impulse, an output will activate a solenoid valve SV, which activates a pneumatic main valve HV, for a certain time propelling liquid will be added to the propelling liquid chamber.

Outlet by the ZSH switch low

If there is too much propelling liquid in the propelling liquid chamber, then the magnet actuates monitoring probe ZSH (switch high), which gives an impulse to an input of the GEHO control box. Due to this impulse an output will activate a solenoid valve SV, which activates a pneumatic main valve HV, for a certain time and propelling liquid will be drained from the propelling liquid chamber.

Description

5.10 201150-IOM-EN-R03

5.6.5.4 Propelling liquid/flushing unit with filling/outlet valves

3 7FILLING OUTLET

1 2 5 6

4 8

Figure 5.7: Propelling liquid valves

1 Filling valves HV1 + HV2 + HV3 (2/2 way hydraulic valve) for filling oil into the propelling liquid chamber.

2 Compressed air supply for actuating the hydraulic valves (1). The air comes from SV1 + SV2 + SV3 (solenoid valves 3/2 way, NC = normal closed).

3 Filling flow into the propelling liquid chamber. 4 Propelling liquid supply from the accumulator.

5 Outlet valves HV5 + HV6 + HV7 (2/2 way hydraulic valve) for outlet of oil from the propelling liquid chamber.

6 Compressed air supply for actuating the hydraulic valves (5). The air comes from SV5 + SV6 + SV7 (solenoid valves 3/2 way, NC = normal closed).

7 Outlet flow from the propelling liquid chamber. 8 Return of oil to the propelling liquid tank.

5.6.5.5 Automatic propelling liquid pressure control

WARNING

The propelling liquid system remains under pressure during operation of the pump and during shut down of the pump, by this accumulator. This is indicated at the pressure gauge.

• Relieve the pressure at this system, by opening the 3-way drain valve at the accumulator line, before working on it.

The pressure in the propelling liquid accumulator is regulated by switching the "FLUSHING VALVE" SV15 of the propelling liquid pump. The position of the valve SV15 is controlled by the pressure transmitter PT6 (connected to the PLC). During steady pump operation this system flushes continuously the pump pistons. If the pressure in the propelling liquid accumulator drops below a preset value, then the SV15 valve closes and the oil flows into the accumulator. If this action exceeds 60 seconds, then the SV15 valve will switch back to flush the pistons for 5 seconds.

Description

201150-IOM-EN-R03 5.11

Flow monitoring at the propelling liquid pump

A flow indicator/switch FISLL is installed in the discharge line of this propelling liquid/flushing pump in order to monitor insufficient oil flow. The switch may generate an alarm signal.

5.6.5.6 Propelling liquid supply valve HV9

The propelling liquid supply valve HV9 supplies the filling valves with propelling liquid from the propelling liquid pump system and prevents the diaphragm housings to be overfilled (for instance caused by leaking filling valves when the main pump is stopped). The propelling liquid supply valve HV9 is actuated by the main motor running signal or manually by push button (see document 814.2TZPM.24) when the pump is not running. After manual operation of the HV9 valve, this valve will stay open for 15 minutes.

5.6.5.7 Automatic outlet program

Program cycle

The automatic outlet program improves the lifetime of the diaphragms. After startup and a speed > 5 SPM (=speed in revolutions per minute of the pump crankshaft) an automatic outlet program for the diaphragm housings will start. 8/10/12 minutes after starting the automatic outlet program the outlet valves will be active during 0.5 second in a time cycle of 5, 9 and 13 seconds. This cycle will be repeated until a filling monitoring probe ZSL of the related diaphragm house is active, then for a certain time propelling liquid will be added to the propelling liquid chamber.

Automatic repeat

After this, the automatic outlet program will repeat the outlet cycle every hour. If during the automatic outlet program a fill monitoring probe ZSL is activated, then the program will switch directly to the next cycle for the related diaphragm house.

5.6.5.8 Propelling liquid failure detection

If at running pump, the fill or outlet system is not able to correct the amount of propelling liquid, within a time of 3 minutes, then the fill/outlet failure detection will be activated. Because the fill or outlet valves are only active for a certain time, an off delay timer of 15 seconds is programmed to extend this signal, which energizes the 3 minutes failure on delay timer. This means that at a speed greater then 4 SPM the valve action will reactivate the off delay timer within 15 seconds and in this way the 3 minute on delay timer for propelling liquid failure will stay active. The propelling liquid failure detection is not active at a pump speed below 4 SPM.


Description

5.12 201150-IOM-EN-R03

Pos: 13.20.1 /GEHO/Heading/H3/#.#.# Pressure limitation system @ 0\mod_1134569743995_31.doc @ 508 @

5.6.6 Pressure limitation system Pos: 13.20.2 /GEHO/Description/Liquid end/Pressure limitation system/Introduction, Elelectrical - Mechanical @ 0\mod_1136292306374_31.doc @ 852 @

A pressure limitation system limits the discharge pressure when a pre-determined pressure is exceeded.

Refer for details and set-points to the document "INSTRUMENT AND EQUIPMENT LIST".

There are independent systems:

• Electrical pressure limitation by stopping the pump drives.

• Mechanical pressure limitation by releasing the propelling liquid. Pos: 13.20.3.1 /GEHO/Heading/H4/Pressure limitation - Electrical @ 0\mod_1136292111124_31.doc @ 846 @

5.6.6.1 Electrical pressure limitation Pos: 13.20.3.2 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - 2-step overpressure @ 0\mod_1136289605881_31.doc @ 824 @

The pressure transmitter raises an alarm, when the operating pressure exceeds a preset alarm level set-point. A further increase of the operating pressure switches off the pump at a second preset level set-point.


NOTE

If the operating pressure is below the precharge pressure of the discharge dampener or air vessel, then the pressure transmitter and the pressure gauge will indicate the precharge pressure (not the lower pump operating pressure).

Refer to chapter "Precharging with nitrogen a pulsation dampener (discharge line)" for dampener precharge instructions. Pos: 13.20.4.1 /GEHO/Heading/H4/Pressure limitation - Mechanical @ 0\mod_1136292155037_31.doc @ 848 @

5.6.6.2 Mechanical pressure limitation Pos: 13.20.4.2 /GEHO/Description/Liquid end/Pressure limitation system/Mechanical @ 0\mod_1136292524278_31.doc @ 854 @

The mechanical pressure limitation system is a secondary safety system. In some cases the pump does not stop immediately due to the mass of inertia forces. In that case the discharge pressure still exceeds the preset trigger level of the electrical pressure limitation system.

A high-pressure manifold connects all diaphragm housing units with a pressure relief valve. The high pressure manifold is connected to all diaphragm housings with a check valve. The check valve prevents oil flow between the diaphragm housings. It also holds a constant line pressure at the underside of the relief valve.

The pressure level in the manifold equals the level of the main pressure spikes in the diaphragm housing units. The safety valve is a spring-loaded type valve with a special valve disc.

If the pressure in the main discharge line exceeds the pressure of the spring, then the safety valve opens and releases the pressure. Pos: 13.20.4.3 /GEHO/Description/Liquid end/Pressure limitation system/Actions after actuating @ 0\mod_1136295398521_31.doc @ 860 @

Actions that follow are:

• Immediate stop of all pumping action.

• A great amount of propelling liquid will be returned to the storage tank.

• The diaphragm moves to the filling position.

• Automatic refill of the propelling liquid system. Pos: 13.20.4.4 /GEHO/Description/Liquid end/Pressure limitation system/Caution - Release pressure @ 0\mod_1136295053785_31.doc @ 858 @

CAUTION

Before installation or service or maintenance work:

• Refer to the concerning chapters.

• Release the pressure from the pressure limitation system.

The pressure limitation system remains under pressure even after shut down of the pump.

Description

201150-IOM-EN-R03 5.13

Pos: 13.21 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @ Pos: 13.22.1 /GEHO/Heading/H3/#.#.# Diaphragm housing unit @ 0\mod_1134569604134_31.doc @ 504 @

5.6.7 Diaphragm housing unit Pos: 13.22.2 /GEHO/Description/Liquid end/Diaphragm housing unit/TZPM @ 0\mod_1135074606766_31.doc @ 699 @

The diaphragm housing unit is the central part of the pump. A rubber diaphragm divides diaphragm housing unit into two sections:

• The propelling liquid section.

• The slurry section.

The movement of the piston generates an increase and decrease of the pressure in the propelling liquid. The diaphragm transmits the pressure change into the slurry section. In combination with the connected valves the slurry will be pumped.

The diaphragm housing unit consists of:

• The diaphragm housing.

• The diaphragm.

• The diaphragm housing cover.

• The monitoring rod.

• The connecting pieces.

The diaphragm is a preformed molded diaphragm with an O-ring shaped clamping ring. This prevents stress concentrations in the clamping area.

The diaphragm housing cover clamps the diaphragm at the diaphragm clamping ring. The diaphragm housing cover and the diaphragm housing have a metal to metal contact. This prevents movement during pump operation and gives the diaphragm a fixed fitting stress in the clamping area. There is a seal between the diaphragm housing cover and the diaphragm housing.

The monitoring rod is connected to a cone plate. The cone plate is vulcanized into the diaphragm. The monitoring rod is part of the propelling liquid control system.

At the propelling liquid section the diaphragm housing unit is connected to:

• The power end unit. Pos: 13.22.3 /GEHO/Description/Liquid end/Diaphragm housing unit/Slurry section/Standard @ 1\mod_1164965667046_31.doc @ 8898 @

At the slurry section the diaphragm housing unit is connected to:

• The suction valve unit at the bottom.

• The discharge valve unit at the top. Pos: 13.23.1 /GEHO/Heading/H3/#.#.# Suction valve unit @ 0\mod_1134569502477_31.doc @ 502 @

5.6.8 Suction valve unit Pos: 13.23.2 /GEHO/Description/Liquid end/Valve units/Suction valve unit @ 0\mod_1137069101509_31.doc @ 1141 @

The suction valve unit allows the slurry to pass from the suction line to the diaphragm housing unit during the suction stroke.

The suction valve unit disallows the slurry to pass from diaphragm housing unit to the suction line during the discharge stroke. Pos: 13.23.3 /GEHO/Heading/H3/#.#.# Discharge valve unit @ 0\mod_1137069603901_31.doc @ 1146 @

5.6.9 Discharge valve unit Pos: 13.23.4 /GEHO/Description/Liquid end/Valve units/Discharge valve unit @ 0\mod_1137069192630_31.doc @ 1143 @

The discharge valve unit allows the slurry to pass from diaphragm housing unit to the discharge line during the discharge stroke.

The discharge valve unit disallows the slurry to pass from the discharge line to the diaphragm housing unit during the suction stroke.

Description

5.14 201150-IOM-EN-R03

Pos: 13.24.1 /GEHO/Heading/H3/#.#.# Suction air vessel unit @ 0\mod_1134632576428_31.doc @ 526 @

5.6.10 Suction air vessel unit Pos: 13.24.2 /GEHO/Description/Liquid end/Air vessel units/Suction/Standard-manual air filling @ 0\mod_1137071003724_31.doc @ 1148 @

The suction air vessel unit minimizes the pressure variations in the suction line. This achieves a constant flow in the suction line.

For most applications the air content in the suction air vessel will not reduce during pump operation even after a long period. In case of an application where air is being transported out of the vessel, then it may be required to install an air filling line to the top of the vessel to allow manually air filling during pump operation. Pos: 13.24.3 /GEHO/Heading/H4/Suction line, under-pressure alarm @ 6\mod_1235737218805_31.doc @ 47911 @

5.6.10.1 Suction line, under-pressure alarm Pos: 13.24.4 /GEHO/Description/Liquid end/Air vessel units/Suction/Pressure transmitter @ 0\mod_1137071352556_31.doc @ 1150 @

A pressure transmitter is located on top of the suction air vessel unit. Pos: 13.24.5 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter-Suction line=1-step under-pressure @ 6\mod_1235737112461_31.doc @ 47901 @

The pressure transmitter raises an alarm, when the suction pressure falls below a preset alarm level set-point.

Refer for details and set-points to the document "INSTRUMENT AND EQUIPMENT LIST". Pos: 13.25 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Description

201150-IOM-EN-R03 5.15

Pos: 13.26 /GEHO/Heading/H3/#.#.# Discharge pulsation dampener @ 0\mod_1134569676478_31.doc @ 506 @

5.6.11 Discharge pulsation dampener Pos: 13.27 /GEHO/Description/Liquid end/Pulsation dampener/Discharge/Introduction @ 0\mod_1147765070988_31.doc @ 3941 @

The discharge pulsation dampener minimizes the pressure variations in the discharge line. This achieves a constant flow in the discharge line. A rubber diaphragm separates the pulsation dampener into 2 sections: • The slurry section. • The nitrogen section, pre-charged with nitrogen. Pos: 13.28 /GEHO/Description/Liquid end/Pulsation dampener/Pressure transmitter+ Refer on P&I-skid @ 1\mod_1173174838995_31.doc @ 12616 @

A pressure measuring point for the pump discharge pressure is located on top of the discharge pulsation damper.

The pressure indicator is located on the P&I-skid (Process and Instruments skid).

The pressure transmitter results are displayed on the GEHO touch panel.

Refer for details to the "INSTRUMENT AND EQUIPMENT LIST" and chapter "Pressure limitation system". Pos: 13.29 /GEHO/Heading/H4/Over pressure alarm @ 0\mod_1136289931970_31.doc @ 828 @

5.6.11.1 Discharge line, over-pressure alarm Pos: 13.30 /GEHO/Description/Liquid end/Pulsation dampener/Pressure transmitter+ Refer on P&I-skid @ 1\mod_1173174838995_31.doc @ 12616 @

A pressure measuring point for the pump discharge pressure is located on top of the discharge pulsation damper.

The pressure indicator is located on the P&I-skid (Process and Instruments skid).

The pressure transmitter results are displayed on the GEHO touch panel.

Refer for details to the "INSTRUMENT AND EQUIPMENT LIST" and chapter "Pressure limitation system". Pos: 13.31 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - 2-step overpressure @ 0\mod_1136289605881_31.doc @ 824 @

The pressure transmitter raises an alarm, when the operating pressure exceeds a preset alarm level set-point. A further increase of the operating pressure switches off the pump at a second preset level set-point.


NOTE

If the operating pressure is below the precharge pressure of the discharge dampener or air vessel, then the pressure transmitter and the pressure gauge will indicate the precharge pressure (not the lower pump operating pressure).

Refer to chapter "Precharging with nitrogen a pulsation dampener (discharge line)" for dampener precharge instructions. Pos: 14 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Transport and installation

201150-IOM-EN-R03 6.1

Pos: 15.1 /GEHO/Heading/H1/#. Transport and installation @ 0\mod_1136455268304_31.doc @ 931 @

6 Transport and installation Pos: 15.2.1.1 /GEHO/Heading/H2/#.# Transport and lifting @ 0\mod_1136806045785_31.doc @ 973 @

6.1 Transport and lifting Pos: 15.2.1.2 /GEHO/General/Attention, Warning and Note/DANGER - Safety - Obey safety instructions and procedures @ 0\mod_1136886637385_31.doc @ 1007 @

DANGER

• Obey the safety instructions.

• Obey the working procedures.

Pos: 15.2.1.3 /GEHO/General/Attention, Warning and Note/Caution - Lifting device - Check for damage @ 0\mod_1136886348800_31.doc @ 1005 @

CAUTION

• Check the lifting devices for damage before use.

• Replace damaged parts immediately.

Pos: 15.2.1.4 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Weight limits @ 0\mod_1136885967642_31.doc @ 1003 @

ATTENTION

• Make sure to use only lifting devices with suitable weight limitation.

Pos: 15.2.1.5 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Protect equipment @ 0\mod_1136886849861_31.doc @ 1009 @

ATTENTION

• Make sure to protect the equipment when using lifting straps or lifting chains.

Pos: 15.2.1.6 /GEHO/General/Attention, Warning and Note/Attention - Lifting locations - Use lifting eyes or flanges @ 0\mod_1136885672808_31.doc @ 1001 @

ATTENTION

• Make sure to use the provided lifting eyes or lifting flanges when hoisting the pump parts.

Pos: 15.2.1.7 /GEHO/Heading/H3/#.#.# Weights and limits @ 0\mod_1137424754577_31.doc @ 1233 @

6.1.1 Weights and weight limits Pos: 15.2.1.8 /GEHO/Transport and installation/Transport and lifting/Caution - Weight limits @ 0\mod_1137425074277_31.doc @ 1237 @

CAUTION

• Never exceed the weight limits.

• Use the correct transport and lifting gear. Pos: 15.2.1.9 /GEHO/Transport and installation/Transport and lifting/Weights @ 0\mod_1137424926404_31.doc @ 1235 @

For the actual transport weights refer to the drawing “PACKING”.

For the actual unit weights refer to the drawing “DIMENSIONED OUTLINE DRAWING”. Pos: 15.2.2 /GEHO/General/Attention, Warning and Note/Warning - Refer to "PACKING" @ 0\mod_1137404858107_31.doc @ 1159 @

WARNING

• Refer to the drawings "PACKING" in chapter "Drawings + Lists + Instruments"

for the lifting values and restrictions. Pos: 15.2.3 /GEHO/General/Attention, Warning and Note/Warning - Hoisting facilities @ 6\mod_1234794998618_31.doc @ 47513 @

WARNING

• Refer to the drawing “HOISTING FACILITY” in chapter "Special tools"

for the lifting locations and recommended tools. Pos: 15.2.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


6.2 201150-IOM-EN-R03

Pos: 15.2.5 /GEHO/Transport and installation/Installation/## Erecting the Installation @ 5\mod_1225119340834_31.doc @ 39879 @

6.2 Erecting the installation

ATTENTION

Before starting erecting the installation, make sure to follow the agreements made between your company and Weir Minerals Netherlands b.v.

WARNING

Strictly adhere to all instructions as given in chapter "Safety" in front of this manual. For safe operation and handling, obey to the instructions in this chapter along with the correct working sequence.

Pos: 15.2.6 /GEHO/Heading/H2/#.# Hoisting Instructions @ 5\mod_1225119514302_31.doc @ 39887 @

6.3 Hoisting instructions Pos: 15.2.7 /GEHO/Transport and installation/Transport and lifting/### Check,, hoisting belts @ 5\mod_1225120147893_31.doc @ 39895 @

6.3.1 General

ATTENTION

• Check always, that the hoisting belts do not touch and damage vulnerable parts of the pump (like instruments, hoses and piping).

Pos: 15.2.8 /GEHO/Transport and installation/Transport and lifting/### lifting eyes @ 5\mod_1221653262294_31.doc @ 38469 @ 3

6.3.2 Lifting eye bolts

WARNING

The heavy parts of the pumps are provided with one or more lifting eye bolts, or have the possibility to install a lifting eye for transportation purposes. • Always transport these parts by using these eyes.

Table according to DIN 580 "LIFTING EYE BOLTS": Working Load Limit (= WLL) [kg]

Size (metric thread)

M8 M10 M12 M16 M20 M24 M27 M30 M33 M36 M42 M56 M64

only for 1 eye bolt, hoisting upwards

140 230 340 700 1200 1800 2500 3600 4300 5100 7000 11500 16000

for 2 or more eye bolts together

95 170 240 500 830 1270 1800 2600 3100 3700 5000 8300 11000

• If 2 or more lifting eye bolts are used, then the minimum hoisting angle is 45 degrees, as shown in the figure.

Pos: 15.2.9.1 /GEHO/Heading/H3/#.#.# Smaller parts @ 0\mod_1136807299788_31.doc @ 985 @ 3

6.3.3 Smaller parts Pos: 15.2.9.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/Smaller parts @ 0\mod_1136809345700_31.doc @ 995 @

• Lift the smaller parts at the desired lifting locations.

• Use lifting straps or a forklift.

Error! Unknown switch argument. Pos: 15.2.10 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 6.3

Pos: 15.2.11.1 /GEHO/Heading/H3/#.#.# Transport the packed installation @ 0\mod_1137408313966_31.doc @ 1177 @

6.3.4 Transport the packed installation Pos: 15.2.11.2 /GEHO/Transport and installation/Transport and lifting/Transport/Transport box @ 0\mod_1137408396926_31.doc @ 1182 @

WARNING

• Obey the instructions at the transport box.

• To lift the transport box, use a crane and lifting chains.

• For fastening the hoisting chains (in case the pump is packed), follow the pictured instructions on both sides of the box.

Figure 6.1: Lifting locations at the transport box (The figure shows a general schematic arrangement, applicable for more versions.)

Pos: 15.2.12 /GEHO/General/Attention, Warning and Note/Warning - Refer to "PACKING" @ 0\mod_1137404858107_31.doc @ 1159 @

WARNING

• Refer to the drawings "PACKING" in chapter "Drawings + Lists + Instruments"

for the lifting values and restrictions. Pos: 15.2.13.1 /GEHO/Heading/H3/#.#.# Drive unit @ 0\mod_1136807338183_31.doc @ 987 @

6.3.5 Drive unit Pos: 15.2.13.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/Drive Unit/Drive unit+gearbox+1hoistspreaders$01 @ 0\mod_1136808534193_31.doc @ 991 @

1 Use a standard hoist spreader (A) to avoid damage (not in the scope of supply).

2 Lift the unit at the 4 frame lifting points (B).

If this kind of hoist spreader is not available, then:

1 Disconnect coupling (C) between the motor and the gearbox.

2 Dis-assemble the motor and gearbox from the frame.

3 Hoist separately the motor and the gearbox and the frame at their hoisting points.

A

C

B1B2

B4B3

Figure 6.2: Lifting locations at the drive unit




6.4 201150-IOM-EN-R03

Pos: 15.2.15.1 /GEHO/Heading/H3/#.#.# Power end @ 0\mod_1136806759712_31.doc @ 979 @

6.3.6 Power end Pos: 15.2.15.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/TZPM/Power end - 2000 ... @ 0\mod_1137413287899_31.doc @ 1204 @

Refer for the required tools to drawing "HOISTING FACILITY" in chapter “Part lists and drawings (special tools)”.

Make sure to use the required transport supports.

Lift the power end at the four lifting flanges (B). The lifting flanges (B) are included in the set of special tools.

B

A

Figure 6.3: Lifting locations at the power end.

(The figure shows a schematic arrangement for more versions)

Pos: 15.2.16.1 /GEHO/Heading/H3/#.#.# Liquid end @ 0\mod_1136807235275_31.doc @ 983 @

6.3.7 Liquid end Pos: 15.2.16.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/TZPM/Liquid end - 2000 ... @ 0\mod_1137400242761_31.doc @ 1152 @

Refer for the required tools to drawing "HOISTING FACILITY" in chapter “Part lists and drawings (special tools)”.

Make sure to use the required transport supports.

Use the hoisting beam (A) and the transport beam (B) to lift the liquid end.

The hoisting beam (A) and the transport beam (B) are included in the set of special tools.

A

B

Figure 6.4: Lifting locations at the liquid end




201150-IOM-EN-R03 6.5

Pos: 15.4 /GEHO/Heading/H2/#.# Installation @ 0\mod_1136888682286_31.doc @ 1015 @

6.4 Installation Pos: 15.5.1 /GEHO/Heading/H3/#.#.# Foundation @ 0\mod_1136888827835_31.doc @ 1021 @

6.4.1 Foundation Pos: 15.5.2 /GEHO/Transport and installation/Installation/Foundation/Foundation bolt schematics @ 0\mod_1136891863740_31.doc @ 1025 @

A Steel foundation bolt B Grout C Diameter of the foundation bolt D Polyurethane foam E Free length of the foundation bolt thread F Diameter (Ø) of the anchor pocket G Depth of the anchor pocket H Height of the Polyurethane foam I Thickness of the covering grout J Angle iron

F

B A

G

H

IE

CD

J

Figure 6.5: Schematics of the anchor pocket and the foundation bolt

Pos: 15.5.3 /GEHO/Transport and installation/Installation/Foundation/Refer to "Dimensioned outline" drawing or "Foundation drawing" @ 0\mod_1136893431935_31.doc @ 1027 @

Refer to the “DIMENSIONED OUTLINE” drawing and/or the “FOUNDATION DRAWING” for the exact sizes and locations of the anchor pockets. Pos: 15.5.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


6.6 201150-IOM-EN-R03

Pos: 15.5.5.1 /GEHO/Heading/H4/#.#.# Mount and level the pump @ 0\mod_1136965605812_31.doc @ 1041 @

6.4.2 Mount and level the pump Pos: 15.5.5.2 /GEHO/Transport and installation/Installation/Foundation/Mount and level/CAUTION Check part numbers @ 6\mod_1234530747188_31.doc @ 47430 @

CAUTION

• Check, before assembling, that the parts numbers are matching with the pump numbers.

Some parts, like the suction line and the discharge line, are sometimes made fitting for one pump number, and labeled accordingly.

Pos: 15.5.5.3 /GEHO/Transport and installation/Installation/Foundation/Mount and level/TZPM/Level - TZPM >= 2000 or Diaphragm housing >= 70 liter @ 3\mod_1203685958407_31.doc @ 26307 @

1 Check the foundation, according to the "DIMENSIONED OUTLINE DRAWING" and/or the "FOUNDATION DRAWING".

2 Place steel blocks next to each anchor pocket. Use steel blocks with a thickness of 50 mm.

3 Level the steel blocks in a range of 1 mm. 4 Lift the pump.

Use a crane. 5 Lift the wet end section.

Use a crane. 6 Move the wet end in it's position against

the power end. 7 Tighten the corner pieces and middle

piece. See nuts (001).

Refer to the chapter “Tightening torques” for the tightening torques.

8 If these parts are not assembled, then install the cylinder liner and piston rod.

Refer to the chapter “Assembly and disassembly", "Piston unit” for install instructions.

9 Remove the power end transport support. 10 Remove hoisting beam wet end and

support beam suction valves. 11 Level the steel blocks in a range of 1 mm. 12 Lift the pump (pump end and wet end).

Use a crane. 13 Put the thread of the foundation bolts into

the borings at the pump. 14 Put the nuts to the foundation bolts. 15 Lower the pump 16 Put the pump to the steel blocks. 17 Make sure that the foundation bolts fit into

the anchor pockets. 18 Hook the foundation bolts in their

dedicated position.

001

Figure 6.6: Connection power end and wet end.


C

AA

B

B

Figure 6.7: Spirit level positions

19 Tighten the nuts at the foundation bolts by hand. 20 Place exactly below all leveling bolts of the pump a plane steel block.

Use steel blocks with a thickness of about 40 mm. 21 Remove 1 cover of a piston cover and crosshead chamber. 22 Place a spirit level (C) on the machined face in direction A-A. 23 Level the pump.

Keep a tolerance of 0.5 mm/m. Use the leveling bolts.

24 Place a spirit level (C) on the machined face in direction B-B.


201150-IOM-EN-R03 6.7

25 Level the pump. Keep a tolerance of 0.5 mm/m. Use the leveling bolts.

26 Fill up the space between the pump and the steel blocks with metal packing shims. 27 Check that the base frame rests on the packing shims. 28 Loosen and remove all leveling bolts. 29 Fill the lower section of all anchor pockets,

to fix all foundation bolts in their position. Refer to the drawing of the anchor pocket.

30 Fill the upper section of all anchor pockets with polyurethane foam. Refer to the drawing of the anchor pocket.

31 Put on a top layer of grout. 32 When the grout is hardened, then tighten all nuts at the foundation bolts.

Make sure to use the correct torques. Refer to chapter "Tightening torques".

Pos: 15.6 /GEHO/Transport and installation/Installation/Auxiliary systems/Auxiliary systems @ 3\mod_1203946338903_31.doc @ 26331 @ 3

6.4.3 Auxiliary systems

1 Mount the support (A) and the pre-assembled auxiliary system to the pump power end.

2 Slide the drip pan (B) between the legs of the support (A).

3 Level the drip pan (B). Use steel shims.

4 Connect the drip pan (B) to the support. Use two brackets (C).

5 Under fill the drip pan (B) with grout. 6 Place the propelling liquid tank (D) over the

drip pan (B). 7 Lock the position of the propelling liquid

tank (D).

A

I

J

F

DBEC

K

G

H

Figure 6.8: Auxiliary system connections


8 Assemble the tubing between the auxiliary system support and the pump:

• Suction line (hydraulic hose) propelling liquid system (E).

• Fill / drain line (F) to each diaphragm house.

• Vent line (G) to side of power end and the propelling liquid tank.

• Nitrogen line (H) to the pulsation dampener(s).

• Drain line (I) flushing box to the propelling liquid tank.

• Drain line (J) pump relief valve to the flushing box.

9 Connect the electrical wiring to the lubrication unit and the drive unit. 10 Connect the instrument airline (K) to the 3/2 valves. Pos: 15.7 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


6.8 201150-IOM-EN-R03

Pos: 15.8.1 /GEHO/Heading/H3/#.#.# Drive unit @ 0\mod_1136807338183_31.doc @ 987 @

6.4.4 Drive unit Pos: 15.8.2 /GEHO/Transport and installation/Installation/Drive unit/Gearbox/Overview @ 0\mod_1136990349612_31.doc @ 1091 @

A Coupling gearbox / pump shaft B Gearbox C Coupling gearbox / motor D Motor E Motor tighten screws F Leveling bolts G Hole for foundation bolts H Metal packing shim I Adjustment screws J Lifting eye K Safety guard

Figure 6.9: Drive unit with gearbox overview


Pos: 15.8.3 /GEHO/Transport and installation/Installation/Drive unit/Gearbox/Mount @ 0\mod_1136903066579_31.doc @ 1039 @ 4

6.4.4.1 Mount the drive unit

1 Place steel blocks (E) next to each anchor pocket.

2 Lift the drive unit. Use a crane.

3 Put the thread of the foundation bolts (C) into the holes at the pump drive base frame (D).

4 Put the nuts to the foundation bolts. 5 Lower the pump drive base frame. 6 Put the pump drive unit to the steel

blocks (E). 7 Make sure that the foundation bolts (C) fit

into the anchor pockets. 8 Hook the foundation bolts in their

dedicated position. 9 Center the gearbox output shaft (A) with

the pump shaft (B). 10 Level the pump drive unit.

Use the leveling bolts at the base frame (D).

C D E

AB

Figure 6.10: Mount the drive unit




201150-IOM-EN-R03 6.9

Pos: 15.8.5 /GEHO/Heading/H4/Gearbox alignment @ 0\mod_1136967931366_31.doc @ 1045 @

6.4.4.2 Gearbox alignment Pos: 15.8.6 /GEHO/Heading/H5/H5 General @ 0\mod_1136967977522_31.doc @ 1047 @ 5

General Pos: 15.8.7 /GEHO/Transport and installation/Installation/Drive unit/General/Introduction @ 0\mod_1136968488297_31.doc @ 1053 @

Shaft couplings need 3 types of alignment: axial alignment + angular alignment + radial alignment (horizontal and vertical). Pos: 15.8.8 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Axial @ 0\mod_1136969611422_31.doc @ 1055 @ 5

Axial alignment:

1 Split-up the spacing between both coupling parts (Snom +/- ∆Ka).

2 Use the adjustment screws at the drive unit base frame.

3 Make sure that the remaining gap is in tolerance. For the correct tolerance values, see the tables below.

Figure 6.11: Axial misalignment.

Pos: 15.8.9 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Angular @ 0\mod_1136976079252_31.doc @ 1059 @ 5

Angular alignment:

1 Align both couplings parts (∆S=S1-S2). 2 Use the adjustment screws at the drive unit

base frame. 3 Make sure that the misalignment ∆S is in

tolerance. For correct tolerance values, see the tables below.

Error! Unknown switch argument.

Figure 6.12: Angular misalignment. Pos: 15.8.10 /GEHO/Transport and installation/Installation/Drive unit/General/Alignment - Radial ESCO @ 0\mod_1136978990869_31.doc @ 1063 @ 5

Radial alignment (horizontal and vertical)

1 Align both coupling parts. 2 Use the adjustment screws at the drive unit

base frame. 3 Measure the "TOTAL INDICATOR

READING" (T.I.R) value (X) during a complete revolution of the coupling.

Refer to chapter “Catalogue information”, "Drive unit" for the "TOTAL INDICATOR READING VALUE" (X)

X

Figure 6.13: Radial misalignment.



6.10 201150-IOM-EN-R03

Pos: 15.8.12 /GEHO/Heading/H5/H4 Gearbox - pump shaft - Pre-alignment @ 0\mod_1136968077676_31.doc @ 1049 @ 4

6.4.4.3 Pre-alignment of the gearbox and the pump shaft Pos: 15.8.13 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/Pre alignment procedure @ 0\mod_1136983950690_31.doc @ 1069 @

Align the gearbox to the pump shaft: 1 Refer to the table below for the alignment tolerance values. 2 Adjust the spacing between both coupling parts (Snom ± ∆Ka). 3 Align both coupling parts in horizontal and vertical direction (∆Kr). 4 Align the angle between the gearbox shaft and motor shaft (∆S). Attach the unit base frame to the foundation: 5 Fill the space between the steel blocks and the drive unit base frame with metal packing shims. 6 Loosen the leveling bolts. 7 Fix all foundation bolts in position. 8 Wait until the grout is hardened. 9 Tighten all foundation bolts with the correct tightening torques. Pos: 15.8.14 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/Alignment tolerances/ZAPEX ZWN 690, no internal gear @ 6\mod_1233761539772_31.doc @ 46873 @

Alignment tolerance values for "FLENDER ZAPEX ZWN" type couplings:

Size [mm]

Pump direct driven Snom [mm]

Axial mis-alignment ∆Ka [mm]

Angular mis-alignment(2) ∆S=S1-S2 [mm]

Radial mis-alignment ∆Kr [mm]

Combined mis-alignment ∆S + ∆Kr [mm]

690 20 -0 / +2.0 0.45 ≤ ∆S ≤ 0.90 0.05° ≤ angle ≤ 0.10°

≤ 0.90 ≤ 0.90

Pos: 15.8.15 /GEHO/General/Attention, Warning and Note/Note (2) Alignment limits @ 0\mod_1136975969234_31.doc @ 1057 @

NOTE

To improve lifetime performance of the teeth of the coupling parts, an intentional angular mis-alignment (in a static condition) is recommended. (2) Minimum limits (lower value) of mis-alignment values are based upon minimum 0.05° angle. Maximum limits (higher value) of mis-alignment values are based upon maximum 0.10° angle. In operation a maximum of 10 fold is allowed (= maximum 1.00° angle of all mis-alignments together, per one coupling half).

Pos: 15.8.16 /GEHO/General/Attention, Warning and Note/Note - Refer alignment information @ 0\mod_1136979880428_31.doc @ 1067 @

NOTE

Refer to chapter “Catalogue information”, "Drive unit" for details about

• safety instructions,

• coupling alignment methods and mis-alignment limits,

• coupling assembly and maintenance. Pos: 15.8.17 /GEHO/Heading/H5/H4 Gearbox - pump shaft - Final alignment @ 0\mod_1136984882160_31.doc @ 1074 @ 4

6.4.4.4 Final alignment of the gearbox and the pump shaft Pos: 15.8.18 /GEHO/Transport and installation/Installation/Drive unit/Gearbox - Pumpshaft/ZAPEX ZWN Final alignment procedure@VERTALINGEN UPDATEN @ 0\mod_1136984368161_31.doc @ 1072 @

CAUTION

Premature wear and resulting damage to the coupling can be caused by: > incorrect alignment of the coupling, > incorrect assembly of the coupling, > incorrect sealing or lubricant of the coupling, > incorrect greasing of the "DUO rings" sealings.

Re-aligning: 1 Re-align the gearbox to the pump shaft as described before. Attaching the gearbox: 2 Fill the space between the gearbox and the base frame.

Use metal packing shims or modify the installed spacer plates. 3 Tighten the gearbox to the drive unit base frame.


201150-IOM-EN-R03 6.11

Coupling assembly:

Refer to document "Catalogue information", "Drive unit", "Coupling" for manufacturer information about > the physical shape of the coupling, > the assembly of the coupling, > how to make the coupling oil leak proof, > filling the coupling with oil.

Refer to document "UTILITY CONSUMPTION LIST" for details about oil type and oil quantity.

4 Grease the surface of the "DUO-rings" (B)

and the groves in cover rings (A). Recommended lubrication grease: > "Shell Alvania RL3". > "Mobil Mobilux EP3".

5 Mount the "DUO-rings" (B) proper in the cover rings (A).

6 Insert generously grease in the ring-shaped space (C) between the sealing lips of the "DUO-rings" (B). To seal properly during operation, the "DUO-rings" (B) sealing lips have to float on a generous grease film. Recommended lubrication grease: > "Shell Alvania RL3". > "Mobil Mobilux EP3".

7 Clean and dry the sealing surfaces (D) of the coupling parts.

F E E FD D D

ABC

ABC

Figure 6.14: Coupling assembly and sealing

8 Cover the sealing surfaces (D) of the coupling parts with a sealing compound. Recommended sealing compound: "LOCTITE 5922 Flange Sealant".

9 Position carefully the cover rings (A) with the "DUO-rings" (B) on the pre-greased coupling shafts. Assure right position of the "DUO-rings" (B) sealing lips.

ATTENTION

If the cover ring (A) is designed as an two-split cover ring, then use the "match marking" on both the cover rings. Do this to avoid deformation of the "DUO-rings" (B).

10 Assemble the coupling covers (E) and cover rings (A) together.

Coupling oil filling: 11 Rotate the coupling,

until the oil screw plugs are in the position, as shown in the figure. D1 = filling plug, D2 = ventilation plug, D3 = drain plug.

12 Remove the two top screw plugs (D1+D2). 13 Measure the correct oil/grease quantity

with a measuring beaker. 14 Fill the coupling with the recommended oil. 15 Screw in all screw plugs (D) with

fitted/integrated sealing rings. 16 Check that the coupling cover does not

leak, by rotating the shaft. Safety protection: 17 Mount the safety guard.

D1 = Filling plug

60°

D3 = Drain plug

D2 = Ventilation plug

60°

30 °

Figure 6.15: Coupling oil filling Pos: 15.8.19 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


6.12 201150-IOM-EN-R03

Pos: 15.8.20 /GEHO/Heading/H5/H4 Motor - Gearbox @ 0\mod_1136968126046_31.doc @ 1051 @ 4

6.4.4.5 Motor and gearbox Pos: 15.8.21 /GEHO/Transport and installation/Installation/Drive unit/Motor - Gearbox/Alignment procedure @ 0\mod_1136985418902_31.doc @ 1081 @

Align the motor to the gearbox: 1 Refer to the table below for the alignment tolerance values. 2 Adjust the spacing between both coupling parts (Snom ± ∆Ka). 3 Align both coupling parts in horizontal and vertical direction (∆Kr). 4 Align the angle between the gearbox shaft and motor shaft (∆S). Attach the motor on the unit base frame: 5 Modify the metal packing shims, if necessary. 6 Tighten the motor to the drive unit base frame. 7 Month the safety guards. Pos: 15.8.22 /GEHO/Transport and installation/Installation/Drive unit/Motor - Gearbox/Alignment tolerances/RUPEX RWN 500 @ 6\mod_1239865913937_31.doc @ 49233 @

Alignment tolerance values for couplings:

Size [mm]

Axial distance Snom [mm]

Axial mis-alignment ∆Ka [mm]

Angular mis-alignment ∆S=S1-S2 [mm]

Radial mis-alignment ∆Kr [mm]

FLENDER RUPEX RWN 500

5.5 ± 1.5 ≤ 0.10 ≤ 0.10

Pos: 15.8.23 /GEHO/General/Attention, Warning and Note/Note - Refer alignment information @ 0\mod_1136979880428_31.doc @ 1067 @

NOTE

Refer to chapter “Catalogue information”, "Drive unit" for details about

• safety instructions,

• coupling alignment methods and mis-alignment limits,

• coupling assembly and maintenance. Pos: 15.9 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 6.13

Pos: 15.10 /GEHO/Transport and installation/Installation/Nitrogen filling/## Safety regulations and instructions for nitrogen @ 0\mod_1156234263710_31.doc @ 5734 @

6.5 Safety regulations and instructions for nitrogen

DANGER

SAFETY Before using a nitrogen bottle equipment:

• Working with a nitrogen bottle equipment is only allowed to authorized and instructed workers.

• Inform about all local legal and insurance policy regulations and safety instructions.

• Inform about all local labor conditions about working with a nitrogen bottle equipment.

• Strictly obey to those regulations and safety instructions.

Refer to the safety instructions of the nitrogen bottle supplier, about how to handle nitrogen, its equipment, and what to do in emergency cases.

DANGER

NITROGEN

Leaking nitrogen (N2) causes lack of oxygen:

• Prevent breathing in nitrogen.

• Be aware of the risk of suffocation, caused by to much nitrogen in the air.

• Prevent nitrogen escaping from the equipment into the working environment.

• Assure in small rooms good ventilation, because of risks of nitrogen leakage.

• Assure free escape routes, because of risks of nitrogen leakage.

DANGER

NITROGEN EQUIPMENT INSTRUCTIONS

• The supply of a nitrogen bottle is not in the scope of Weir Minerals.

Refer to "Catalogue information" for instructions and information of the manufacturer about safe and proper user of the nitrogen bottle and nitrogen charging equipment.

If the nitrogen charging equipment is not in the scope of Weir Minerals, then refer to instructions and information of the manufacturer about safe and proper use.

• Make sure that the maximum pressure in the nitrogen bottle does not exceed the maximum permitted pressure of the pressure regulator.

• Make sure that the equipment is in good condition. Pos: 15.11 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


6.14 201150-IOM-EN-R03

Pos: 15.12 /GEHO/Heading/H2/#.# Pre-charging with nitrogen a pulsation dampener (discharge line) @ 5\mod_1231340599275_31.doc @ 45123 @

6.6 Pre-charging with nitrogen a pulsation dampener (discharge line) Pos: 15.13 /GEHO/Heading/H3/#.#.# Pre-charging the discharge pulsation dampener, set-point instructions @ 1\mod_1173202078632_31.doc @ 12640 @

6.6.1 Pre-charging the discharge pulsation dampener, set-point instructions Pos: 15.14 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/#### Discharge pulsation dampener, pre-charge definitions @ 0\mod_1156257465577_31.doc @ 5764 @ 44 discharge

6.6.1.1 Discharge pulsation dampener, pre-charge definitions

Definitions Comment Refer to

pump system, maximum pressure

maximum allowed pressure for the pump system

pump identification plate

pump system, "normal" pump operating pressure

operating pressure will change during operation, depending on many factors

pump discharge pressure indicator + "GEHO TOUCH PANEL", graphics menu: "ACTUAL VALUE"

pump system, maximum pump operating pressure

operating pressure maximum, that occurs while operating

pump discharge pressure indicator + "GEHO TOUCH PANEL", graphics menu"HIGHEST VALUE"

dampener system, maximum system pressure

maximum allowed pressure for the dampener system

dampener system identification plate + chapter "Technical data"

dampener, range

maximum allowed pressure for this part

"INSTRUMENT AND EQUIPMENT LIST" + pulsation dampener identification plate

dampener, pre-charge set-point

recommendation to start with by installation, may need re-adjustment, depending on operation conditions

"INSTRUMENT AND EQUIPMENT LIST" + after pre-charging, read the pressure indicator on the dampener (only if there is no pressure at the slurry side of the diaphragm)

dampener, diaphragm limit

pre-charge limit to prevent extrusion of the diaphragm material at the dampener in-/out-let

"INSTRUMENT AND EQUIPMENT LIST" + chapter "Technical data"

6.6.1.2 Discharge pulsation dampener, pre-charge set-point instructions

DANGER

Safety limits: To prevent over-stressing the dampener system and the diaphragm:

• NEVER pre-charge the pulsation dampener with more then the dampener system, maximum pressure. The maximum pressure is indicated on the pulsation dampener identification plate.

• NEVER pre-charge the pulsation dampener with more then the maximum pressure limit of the diaphragm. The pressure limit of the diaphragm is indicated in chapter "Technical data".

ATTENTION

Functional limits:

To prevent dampener diaphragm damage during pressure still-stand of the pump

and hammering of the diaphragm against the bottom of the dampener:

• NEVER pre-charge the pulsation dampener with more then 80% of the maximum pump operating pressure.

To prevent hammering of the diaphragm against the top of the dampener:

• NEVER let the pre-charge pressure drop below 30% of the maximum pump operating pressure.

Excessive pressure pulsations and heavy vibrations are caused by insufficient pre-charge pressure.


201150-IOM-EN-R03 6.15

ATTENTION

The pre-charge pressure may change due to temperature influence:

• Temperature fluctuation of the slurry.

• Temperature differences between the slurry and the environment.

These effects require re-adjustment of the pre-charge pressure. The pre-charge pressure is application dependent.

Refer to document "INSTRUMENT AND EQUIPMENT LIST" for details about the "discharge pulsation dampener".

Refer to document "INSTRUMENT AND EQUIPMENT LIST" for the dampener pre-charge "SET-POINT" recommendation for installation, to start with.

Operating conditions Recommended pre-charge set-point

Percentage of operating pressure

Result

80% = maximum pre-charge limit, but NEVER more then the diaphragm limit, as indicated in document "INSTRUMENT AND EQUIPMENT LIST".

to protect the diaphragm and the dampener

constant operating pressure 60% to 65% optimal operation

widely varying operating pressure 30% to 35% optimal operation

30% = minimum pre-charge limit to protect the diaphragm and dampener

NOTE

High dampener pre-charge pressure (related to the operating pressure) gives the best dampening results.

If the operating pressure decreases, then this can cause wear and damage to the diaphragm and metal insert, by continuously hammering at the dampener bottom.

If working with relatively constant pump pressures, then the GEHO diaphragm pulsation dampeners are to be charged at 60% - 65% of the pumps normal operating pressure (see "GEHO TOUCH PANEL", menu "GRAPHICS": "ACTUAL VALUE").

If operating the pump with widely varying pressures, then it can be necessary to pre-charge the pulsation dampener at 30% - 35% of the pumps maximum operating pressure (see "GEHO TOUCH PANEL", menu "GRAPHICS": "HIGHEST VALUE").



6.16 201150-IOM-EN-R03

Pos: 15.16 /GEHO/Heading/H3/#.#.# Pre-charging a pulsation dampener with the nitrogen filling device @ 1\mod_1173344002199_31.doc @ 12672 @

6.6.2 Pre-charging a pulsation dampener with the nitrogen filling device Pos: 15.17 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/#### Dampener-Nitrogen R03 bottle+charging equipment 2+more connections old fig. @ 3\mod_1203094745983_31.doc @ 26234 @ 4

6.6.2.1 Nitrogen bottle with charging equipment

DANGER

• Usually not in the scope of supply of Weir Minerals are the nitrogen filling equipment parts

(nitrogen bottle, pressure reducer, safety valve and drain valve).

• Check that they are in accordance with local standards and safety regulations.

A Nitrogen bottle B Nitrogen bottle valve R Safety relieve,

to protect the pulsation dampener against overload. Relieve pressure depends on the maximum allowed pressure of the pulsation dampener.

Nitrogen pressure regulator unit: C Pressure regulator C1 Pressure gauge indicating the bottle pressure C2 Pressure gauge indicating the actual filling

pressure in the hose C3 Pressure reducer valve D High pressure hose Nitrogen filling device: E Pressure gauge pulsation dampener F Filling valve pulsation dampener G Fixed connection to working pressure

transmitter H High pressure hose connection I Fixed connection to pulsation dampener N Pulsation dampener

N

I

A D

C

B

C2C1

C3

R

I

FG

EH

Figure 6.16: Pre-charging the pulsation dampener with the nitrogen filling device

The figures show a general schematic arrangement, applicable for more versions with 2 or more pulsation dampeners.



201150-IOM-EN-R03 6.17

Pos: 15.19 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/Pulsation dampener R03 pre-charging procedure using the nitrogen fill. (fill connect 2+more) old fig @ 3\mod_1203327402790_31.doc @ 26243 @ 44444

6.6.2.2 Pulsation dampener pre-charging procedure

DANGER

Refer to chapter "Safety regulations and instructions for nitrogen".

DANGER

INSTRUCTIONS ABOUT FILLING A PULSATION DAMPENER WITH NITROGEN (N2)

Refer to "Instrument and equipment list" and the begin of this chapter, for the recommended pre-charge set-point pressure of a pulsation dampener.

• Always pre-charge the GEHO pulsation dampeners with nitrogen gas (N2), before operating the pump.

• ONLY use nitrogen gas (N2) to pre-charge the dampener. • NEVER use oxygen (or air containing oxygen) to pre-charge the dampener.

There is a risk of explosion. • ONLY use an appropriate pressure regulator to pre-charge the pulsation dampener. • Be aware of the risk, that the dampener pressure gauge indicates a wrong pressure.

The pressure sensing opening may be clogged. The pulsation dampener may be under pressure, even when the dampener pressure gauge indicates no pressure.

• Risk of explosion of the dampener. An external fire will increase the nitrogen pressure inside the pulsation dampener. The designed pressure can be exceeded.

DANGER

Before starting the dampener pre-charge procedure:

• Make sure that there is no pressure at all connections of the pulsation dampener. • Make sure that there is no liquid at the slurry side of the diaphragm.

Measuring pre-charge pressure with liquid or pressure at the slurry side of the diaphragm gives wrong indications about the pre-charge situation.

• NEVER change the nitrogen charge of the dampener during operation of the pump, for measured pressure values will not relate to the nitrogen volume in the dampener.

6.6.2.3 Pre-charge pressure check

1 Read the actual pre-charge pressure of the pulsation dampener (N) at its pressure indicator (E) on the nitrogen filling device.

2 If the pre-charge pressure is higher then the desired pre-charge pressure, then: • Vent a little amount of nitrogen by opening the filling valve (F). • Check the actual pre-charge pressure of the pulsation dampener (N) at its pressure indicator (E) • Repeat this pulsation venting, until the recommended pre-charge pressure is reached.

3 If the actual pre-charge pressure is lower then the pre-charge pressure, then follow this procedure to add nitrogen.

6.6.2.4 Preparation

Follow these steps only, when fixed connection will be assembled.

1 Connect the pressure regulator (C) to the nitrogen bottle (A+B).

2 Connect the safety valve (R) and Relieve valve (S) to the pressure regulator (C)

3 Connect the hose (D) to the safety valve (R).

4 Connect the hose (D) to the filling valve connection (H) of the nitrogen filling device.


6.18 201150-IOM-EN-R03

6.6.2.5 Nitrogen pre-charge filling

1 Set the nitrogen pressure regulator (C) with pressure relieve valve (C3) to the according dampener pre-charge pressure.

2 Open the nitrogen bottle valve slowly (B).

• Check at gauge (C1) the bottle pressure, it has to be more than the recommended pulsation dampener pressure.

• Check gauge (C2) that the pressure is zero.

3 Open the pulsation dampener filler valve (F).

4 Open the pressure reducer valve (C3) slowly.

5 The actual filling is now started.

DANGER

• Prevent fast filling.

It will cause icing at the valves and the hose.

6 Open pressure reducer valve (C3) in many small steps, until the recommended pre-charge pressure is reached at gauge (C2) and gauge (E).

7 Close the pulsation dampener filler valve (F) when the pre-charge pressure is reached.

6.6.2.6 Disconnect

1 Interrupt the nitrogen supply by closing the nitrogen bottle valve (B).

2 Flush the hose (D) by loosen the filling valve connection (H) a little bit. The hose pressure will drop to pressure zero.

3 Close the pressure reducer valve (C3).

4 Disconnect the pressure regulator (C) from the nitrogen bottle (A+B).

5 Disconnect the safety valve (R).

6 Disconnect hose (D) from the filling valve connection (H) of the nitrogen filling device.



201150-IOM-EN-R03 6.19

Pos: 15.21 /GEHO/Heading/H2/#.# Pre-charging the accumulator with nitrogen @ 5\mod_1231340368299_31.doc @ 45103 @

6.7 Pre-charging an accumulator with nitrogen Pos: 15.22 /GEHO/Transport and installation/Installation/Nitrogen filling/#### Accu N2 Safety regulations @ 1\mod_1169741864089_31.doc @ 12018 @ 4

6.7.1.1 Accumulator safety regulations and procedure instructions

DANGER

SAFETY Before using a nitrogen bottle equipment:

• Working with a nitrogen bottle equipment is only allowed to authorized and instructed workers.

• Inform about all local legal and insurance policy regulations and safety instructions.

• Inform about all local labor conditions about working with a nitrogen bottle equipment.

• Strictly obey to those regulations and safety instructions.

DANGER

NITROGEN

Leaking nitrogen (N2) causes lack of oxygen:

• Be aware of the risk of suffocation, caused by to much nitrogen in the air.

• Prevent nitrogen escaping from the equipment into the working environment.

• Prevent breathing in nitrogen.

DANGER

EQUIPMENT

• Always pre-charge the accumulator with nitrogen gas (N2), before operating the pump.

• ONLY use nitrogen gas (N2) to pre-charge the accumulator.

• NEVER use oxygen (or air containing oxygen) to pre-charge the accumulator. There is a risk of explosion.

• ONLY use an appropriate pressure regulator to pre-charge the accumulator.

• Make sure that the equipment is in good condition.

• Risk of explosion. An external fire will increase the nitrogen pressure inside the accumulator. The designed pressure will be exceeded.



6.20 201150-IOM-EN-R03

Pos: 15.24 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/#### Nitrogen bottle+charging equipment+accumulator+safety valve @ 4\mod_1210236627950_31.doc @ 29246 @ 4

6.7.1.2 Nitrogen bottle with charging equipment, accumulator

DANGER

Nitrogen bottle and pressure reducer are usually not in the scope of supply of Weir Minerals.

• Check that they are in accordance with local standards and safety regulations.

A Nitrogen (N2) bottle

B Nitrogen bottle main manual valve

C Pressure reducer:

D Pressure gauge, indicating the bottle pressure

E Pressure gauge, indicating the actual filling pressure in the hose

F Pressure reducer valve

G Charging hose for high pressure nitrogen charging

A B C D E O F G H I J K L M N

Figure 6.17: Nitrogen bottle with charging equipment


H Charging unit: I Non-return valve (prevents gas to flow out of the accumulator) J Shut-off-valve K Manual valve for pressure relief L Pressure gauge indicating the actual filling pressure M Accumulator N 3/2 manual ball valve, with drain side to release the pressure at the fluid side of the accumulator O Safety relieve valve, to protect the accumulator against pressure overload.

The relieve pressure depends on the maximum allowed pressure of the accumulator and the charging equipment.



201150-IOM-EN-R03 6.21

Pos: 15.26 /GEHO/Transport and installation/Installation/Nitrogen filling/Pre-charging/#### Accu-N2-pre-charging procedure with safety valve @ 1\mod_1169741590336_31.doc @ 12010 @ 444444

6.7.1.3 Accumulator pre-charging procedure

DANGER

Refer to chapter "Safety regulations and instructions for nitrogen".

DANGER

ACCUMULATOR INSTRUCTIONS

Refer to document "INSTRUMENT AND EQUIPMENT LIST" for the correct pre-charge pressure of the accumulator.

CAUTION

Prior to each testing, topping-up or re-charging the accumulator with nitrogen, de-pressurize the fluid side of the accumulator. If pressure remains at the fluid side of the accumulator, then that leads to a wrong combination of nitrogen volume and pressure. That will affect the function of the accumulator.

6.7.1.4 Primer pre-charge pressure check

1 Shut down the pump for maintenance.

2 Open the drain side of 3/2 ball valve (N), to drain pressure at the fluid side of the accumulator. Depending on the lay-out details: • Keep fluid in the piping below the accumulator. • Prevent that air fills the fluid compartment of the accumulator.

3 Make sure that shut-off-valve (J) is closed.

4 Make sure that relieve valve (K) is closed.

5 Remove the protection cap at the top of the accumulator (M). Mount charging unit (H) on accumulator (M).

6 Open the shut-off-valve (J).

7 Read the actual pre-charge pressure of the accumulator with the pressure gauge (L).

If the accumulator is filled with a higher pressure than recommended,

then release the pressure until the recommended value:

8 Open the pressure relief valve (K) a few seconds just a bit. This will allow nitrogen to escape, reducing the pressure in the accumulator. • Repeat this, until the recommended pre-charge pressure is reached.

9 If the pressure is according to the recommended value, then • Close the drain side of 3/2 ball valve (N) to allow fluid pressure at the fluid side of the accumulator. • The pressure check procedure is finished.

10 If the accumulator is filled with a lower pressure than recommended, then use the filling procedure below.

6.7.1.5 Filling preparation

1 Close the pressure reducer valve (F).

2 Connect the pressure reducer (C) to nitrogen bottle (A+B).

3 Connect the hose (G) to pressure reducer (C).

4 Open the nitrogen bottle valve (B) slowly. • Check at the gauge (D) the pressure in the bottle, it has to be more than the recommended accumulator pressure. • Make sure that the pressure at the gauge (E) is zero and the valve (F) is closed.

5 Flush the hose clean short by open little a second and immediately close pressure reducer valve (F).


6.22 201150-IOM-EN-R03

6 Connect the hose (G) to the charging unit (H).

6.7.1.6 Nitrogen pre-charge filling

1 Open the shut-off-valve (J).

2 Open the pressure reducer valve (F) in many small steps, until the recommended pre-charge pressure is reached at gauge (E) and gauge (l).

DANGER

Prevent fast filling, because it will cause icing at the valves and the hose.

3 If the recommended pre-charge pressure is reached, then:

4 Close the nitrogen bottle valve (B), so the nitrogen supply is interrupted.

5 Close the pressure reducer valve (F).

6 Close the shut-off-valve (J), so the accumulator is isolated.

7 To release the nitrogen pressure in the hose: Open the pressure relief valve (K). • Make sure that the pressure is zero at the gauge (L). • Make sure that the pressure is zero at the gauge (E).

6.7.1.7 Disconnect the nitrogen supply line

1 Make sure, that nitrogen bottle valve (B) is closed.

2 Disconnect the pressure regulator (C) from nitrogen bottle (A+B).

3 Disconnect the hose (G) pressure regulator (C+O).

4 Disconnect the hose (G) from charging unit (H).

6.7.1.8 Return to operation.

1 If charging unit (H) stays at the accumulator, then: • Leave the shut-off-valve (J) shut. • Read the fluid pressure only at the pressure gauge at the fluid side, not at gauge (I). • Check for leakages on valve (J) and its connection to the accumulator, using a leak detector spray.

2 If removing charging unit (H), then: • Disconnect the charging unit (H) from accumulator (M). • Check for leakages on the accumulator top, using a leak detector spray. • Mount the protection cap at the top of the accumulator (M).

3 Close the drain side of the 3/2 ball valve (N), to allow fluid pressure at the fluid side of the accumulator. Pos: 16 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Operation, Start-up + Start + Stop procedures

201150-IOM-EN-R03 7.1

Pos: 17.1 /GEHO/Heading/H1/#. Operation, Start-up + Start + Stop procedures @ 0\mod_1136455316013_31.doc @ 933 @

7 Operation, Start-up + Start + Stop procedures Pos: 17.2 /GEHO/Heading/H2/## Start-up checklist, GEHO + VFD main power switch OFF @ 2\mod_1173875659029_31.doc @ 12732 @ 2

7.1 Start-up, working with the GEHO + VFD main power switch OFF

ATTENTION

• Use this procedure, to make the pump system ready for operation (at first at installation, and after working on the pump).

• Secure the main power switches against "unwanted switch-on".

VFD = "VARIABLE FREQUENCY CONVERTER DEVICE" that regulates the speed of the main motor.

Pos: 17.3 /GEHO/Start and Stop/Common/Warning - Heavy parts - Use hoisting eye @ 1\mod_1165935566336_31.doc @ 9221 @

WARNING

The heavy parts of the pumps are provided with a hoisting eye or have the possibility to install a hoisting eye for transportation purposes.

• Always transport these parts by using these hoisting eyes. Pos: 17.4 /GEHO/Heading/H3/#.#.# Initial lubrication filling @ 1\mod_1171376311244_31.doc @ 12412 @

7.1.1 Initial lubrication filling Pos: 17.5 /GEHO/Start and Stop/Common/Lubrication - Initial @ 1\mod_1165995657192_31.doc @ 9251 @

If applicable, then check and perform an initial lubrication filling of the following parts.

7.1.1.1 Gear box (if applicable):

1 Check the oil level in the gearbox. 2 If the gearbox has an oil cooling system and/or oil filters,

then check the oil level again, immediately after starting the oil circulation, to ensure, that the circulation system is filled properly.

3 If necessary, then add or drain oil until the right level is reached.

Refer to chapter "Appendix: Catalogue information" for details about the procedure. Refer to document "UTILITY CONSUMPTION LIST" for details about the oil type and oil quantity.

7.1.1.2 Tooth coupling between gearbox and pump shaft (if applicable):

Refer to chapter "Installation", "Drive unit" for details. Refer to chapter "Appendix: Catalogue information" for details about the procedure. Refer to document "UTILITY CONSUMPTION LIST" for details about the oil type and oil quantity.

7.1.1.3 Power end:

Working with the main power switch OFF:

1 Clean the power end side, if necessary. 2 Open the main covers. 3 Open the side covers. 4 Clean the crosshead liners. 5 Fill the oil sump with oil.

Use a combined oil-filter/oil-water-separator to clean the oil.

Refer to document "UTILITY CONSUMPTION LIST" for details about the oil type and oil quantity.

6 Check the oil level gauge. At initial filling or re-filling, the oil level should be near level (B).

7 Close all covers.

B

A

Figure 7.1: Correct oil filling level at the oil level gauge


7.2 201150-IOM-EN-R03

Working with the main power switch ON at the GEHO control box:

8 Check the direction of rotation of the lubrication pump.

Refer to chapter "Start-up, electrical check".

9 Start the lubrication pump. 10 Check the oil level gauge.

After 5 minutes, oil is distributed in the lubrication system and the oil level should be about half height at the oil level gauge, near level (A). If necessary, then fill additional oil until level (A).

11 Check the lubrication system.

Continue working with the main power switch OFF at the GEHO control box. Pos: 17.6 /GEHO/Heading/H3/#.#.# Propelling liquid @ 1\mod_1166007118791_31.doc @ 9297 @

7.1.2 Propelling liquid Pos: 17.7 /GEHO/Start and Stop/Propelling liquid - Initial @ 1\mod_1165936154067_31.doc @ 9227 @

Refer to document "UTILITY CONSUMPTION LIST" for details about the oil type and oil quantity.

1 Open the propelling liquid tank cover. 2 Clean the propelling liquid tank. 3 Fill the propelling liquid tank to the upper liquid level. 4 Check the liquid level at the liquid level gauge. 5 Close the propelling liquid tank cover. Pos: 17.8 /GEHO/Heading/H3/#.#.# Air supply unit @ 0\mod_1146140424938_31.doc @ 3465 @

7.1.3 Air supply unit Pos: 17.9 /GEHO/Start and Stop/Common/Air supply check @ 1\mod_1165998689770_31.doc @ 9254 @

ATTENTION

• Air pressure must ALWAYS be available, even when the slurry pump is not in operation. Without air pressure, the pump system will stop immediately by a pressure alarm, or soon by an electric operation control alarm. Because the air valves are spring-opened, air pressure is necessary to avoid liquid-loss or liquid-overfilling in the propelling liquid chambers.

• Check that pressure and quality and quantity of the compressed air supply meet the requirements.

Refer to document "UTILITY CONSUMPTION LIST" in chapter "Technical data" for details about the compressed air supply.

• Check that the air supply line is flushed clean, before connecting it to the pump system.

• Connect the compressed air supply. Pos: 17.10 /GEHO/Heading/H3/#.#.# Pre-charging an accumulator @ 4\mod_1208245317652_31.doc @ 28482 @

7.1.4 Pre-charging an accumulator Pos: 17.11 /GEHO/Start and Stop/Common/Pre-charge accumulator-gas @ 1\mod_1170093129172_31.doc @ 12048 @

The accumulator of the propelling liquid system must be pre-charged with gas.

Refer to document "INSTRUMENT AND EQUIPMENT LIST" for the correct pre-charge pressure.

Refer to document "UTILITY CONSUMPTION LIST" for the gas quality.

Refer to the chapter "Installation" for the pre-charging procedure and set-point.

Refer to the chapter "Transport and installation", "Pre-charging the accumulator" for the procedure. Pos: 17.12 /GEHO/Heading/H3/#.#.# Procedure pre-charging a pulsation dampener with nitrogen @ 0\mod_1156314333839_31.doc @ 5777 @

7.1.5 Procedure pre-charging a pulsation dampener with nitrogen Pos: 17.13 /GEHO/Start and Stop/Common/Pre-charge pulsation dampener, refer to installation @ 1\mod_1169653974927_31.doc @ 11992 @

Refer to chapter "Transport and installation", "Pre-charging the pulsation dampener" for the procedure.

• Check that the pulsation dampener is pre-charged with nitrogen, according to the procedure. Pos: 17.14 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 7.3

Pos: 17.15 /GEHO/Heading/H2/## Start-up checklist, GEHO main power switch=ON, VFD=OFF @ 2\mod_1173875689375_31.doc @ 12737 @ eparation

7.2 Start-up checklist, working with the GEHO main power switch ON

DANGER

• Make sure that the power of the main motor and its VFD is switched OFF. • Secure the main power switch of the main motor and its VFD against "unwanted switch-

on".

VFD = "Variable Frequency converter Device " that regulates the speed of the main motor.

ATTENTION


Pos: 17.16 /GEHO/Heading/H3/#.#.# Main power switch @ 1\mod_1166007056288_31.doc @ 9294 @

7.2.1 Main power switch Pos: 17.17 /GEHO/Start and Stop/Common/Start-up, main power supply @ 1\mod_1170157413431_31.doc @ 12075 @

DANGER

From this step on, to proceed the "Start, preparation check list", electric main power supply is needed only at the GEHO Pump Control System and its GEHO HMI PANEL.

Pos: 17.18 /GEHO/Start and Stop/Common/Start-up, main power switch = (T)ZPM+DH+APEX @ 1\mod_1165998832165_31.doc @ 9257 @ 5

DANGER

While working on the pump, it is not permitted to start the pump.

• If working during maintenance or service, then set the main motor power switch to the 0-position (OFF) and lock the switch.

• Secure the main motor power switch against "unwanted switch-on", until the pump system is safe to run.

• NEVER switch on the main motor power switch, until the pump system is safe to run.

Operation at the "GEHO HMI PANEL"

1 Check that the pump "EMERGENCY STOP SYSTEM" is operational.

2 Check, that the pump system is safe to switch on and run.

3 Switch the main switch at the "GEHO HMI PANEL" to the 1-position (= ON). Pos: 17.19 /GEHO/Heading/H3/#.#.# Start-up, electrical check @ 1\mod_1170159443932_31.doc @ 12080 @

7.2.2 Start-up, electrical check Pos: 17.20 /GEHO/Start and Stop/Common/Start-up, electric check @ 1\mod_1170159737562_31.doc @ 12084 @

1 Ask an authorized electrician to check that the auxiliary electric motors turn in the direction, as indicated on the motor cover or on the pump power end.

2 If a motor turns in the wrong direction, then change the electrical connections.

Pos: 17.21 /GEHO/Start and Stop/Common/Start-up, power end oil check @ 2\mod_1173876188272_31.doc @ 12742 @

7.2.3 Initial power end oil check

1 Check the oil level at the power end.

Refer to chapter "Initial lubrication filling". Pos: 17.22 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


7.4 201150-IOM-EN-R03

Pos: 17.23 /GEHO/Heading/H2/## Start-up, priming procedure @ 2\mod_1175856788072_31.doc @ 13082 @ eparation

7.3 Start-up, priming procedure

ATTENTION


Pos: 17.24 /GEHO/Heading/H3/#.#.# Priming the slurry section @ 1\mod_1166006925672_31.doc @ 9288 @

7.3.1 Priming the slurry section Pos: 17.25 /GEHO/Start and Stop/TZPM/Priming the slurry section @ 1\mod_1166001286915_31.doc @ 9269 @ 44555

7.3.1.1 Targets of priming the slurry section:

1. De-aeration of the slurry section, by filling water via a flushing water connection (D) in the suction line and draining the water through valve (B) in the discharge line.

2. De-aeration of each propelling liquid chamber through valves (E) and (G) and (F).

3. To obtain a controlled starting position for filling all propelling liquid chambers, the flush water pressure will force the diaphragm against the rear wall of the diaphragm housing, where position marker (M) meets switch (ZSL).

ATTENTION

Refer to document "UTILITY CONSUMPTION LIST" for the required flush water quality and quantity and pressure.

7.3.1.2 Procedure filling the slurry section with flush water and de-aeration

Figure 7.2: Filling and de-aerating the slurry section


1 Start up the air unit (needed for proper function of the propelling liquid system).

Closing the slurry section:

2 Close the main valve (C) in the suction line. 3 Close the main valve (A) in the discharge line.

De-aerating the slurry section:

4 Open valve (D) of the flush water connection to the suction line.

Refer to document "UTILITY CONSUMPTION LIST" for the flush water quality and quantity and pressure.

5 Open the drain valve (B) in the discharge line. Wait until flush water discharges from the drain valve (B).


201150-IOM-EN-R03 7.5

6 Close the drain valve (B).

De-aerating the propelling liquid chambers and positioning the diaphragms in starting position:

7 Partly open drain valve (B) in the discharge line, to maintain in the slurry section a pressure, as specified in the document "UTILITY CONSUMPTION LIST". • The pressure of the flush water must be high enough to force the propelling liquid to escape through non-return-valve (F).

8 Open the vent valves (E) of all propelling liquid chambers (located on the rear side top of the diaphragm housing). The flush water pressure moves all diaphragms in the priming start position (ZSL). Position marker (M) of each diaphragm rod meets switch (ZSL) and at the GEHO touch panel its light will light on.

9 Check at the GEHO touch panel, that the lights of switch (ZSL) of all pistons light on. 10 Continue with the next chapter, to prime the propelling liquid section. 11 Continue with the next chapter, to prime the propelling liquid section. Pos: 17.26 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


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ATTENTION

Refer to document "UTILITY CONSUMPTION LIST" for the required flush water quality and quantity and pressure.

Figure 7.3: Schematics of the TZPM propelling liquid section


De-aeration of the propelling liquid section:

1 Refer to the previous chapter to fill the slurry section with flush water and to move each diaphragm with rod indicator (M) in its priming start position (ZSL).

2 Open the flush water connection (D) in the suction line. 3 Partly open the drain valve (B) in the discharge line, to maintain in the slurry section a pressure,

as specified in the document "UTILITY CONSUMPTION LIST". • A diaphragm needs pressure at both sides, to move properly. • The pressure of the flush water must be high enough to force the propelling liquid to escape through non-return-valve (F).

4 Start at the "GEHO TOUCH PANEL" the propelling liquid pump. 5 Open the vent valves (E) in the propelling liquid section of all diaphragms. 6 Open the vent valve (G) to de-aerate the common line at safety relief valve (H) of the propelling liquid

system. 7 Push at the "GEHO TOUCH PANEL" the button "MAIN SUPPLY VALVE", to open the main supply

filling valve (K) for 15 minutes.

Refer to document "P&I DIAGRAM" for details about the propelling liquid automatic control system. Refer to the "GEHO TOUCH PANEL" and its manual for details about how operation conditions are displayed at the panel.

8 Close the vent valves (E) and (G), if the propelling liquid, that discharges through valve (F), contains no air bubbles.

9 If necessary, then repeat the steps 7 and 8 until all vent valves (E) of the diaphragms are closed. 10 After de-aeration, as long as a filling valve is open,

• propelling liquid will be filled into the pump chambers; • the diaphragms will leave the ZSL start position; • until the monitoring rods of the diaphragms de-activate the ZSL indicators;


201150-IOM-EN-R03 7.7

• the corresponding filling valves will close, the filling will stop; • at the "GEHO TOUCH PANEL" the corresponding diaphragm position light (ZSL) will turn off.

11 If necessary, then repeat step 7 until at the "GEHO TOUCH PANEL" all position lights of all diaphragms are off.

Positioning of the diaphragms in relation to the pistons:

ATTENTION

Avoid that the pump rotates without lubrication. 12 Start the lubrication pump. 13 Check that the lubrication system delivers the oil quantity.

14 Rotate the pump crankshaft manually.

DANGER

• Make sure that the power of the drive motor is switched off.

Refer for details to the chapter "Manual rotation of the pump".

15 If at the "GEHO TOUCH PANEL" one of the lights of switch (ZSH) or (ZSL) of the diaphragm position is lit, then stop rotation of the pump. • If indicator (M) meets switch (ZSL), so related switch light is lit, then the propelling liquid system will fill propelling liquid, until the indicator light is off. • If indicator (M) meets switch (ZSH), so related switch light is lit, then the propelling liquid automatic control system will drain propelling liquid, until the switch light is off.

16 Wait until this switch light is off. 17 Repeat steps 10 to 12 until no switch lights light up during rotation of the pump. 18 Turn the pump crankshaft another 2 turns, to check that no switch lights light up.

So all chambers are filled properly with propelling liquid and piston rod indicator (M) of the diaphragm moves properly between switch (ZSL) and switch (ZSH).

Arranging PRE-START of the pump

19 Close the drain valve (B) in the discharge line. 20 Close the flush water valve (D) of the flushing water connection in the suction line. 21 Stop the flush water supply. 22 Open the main valve (C) in the suction line. 23 Open the main valve (A) in the discharge line. Pos: 17.29 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


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7.4 Operating the GEHO Touch Panel + GEHO Pump Control System Pos: 17.31 /GEHO/Start and Stop/Common/Operating touch panel LOCAL+REMOTE_R01 @ 1\mod_1169830665787_31.doc @ 12021 @ 3455355

Refer to document "TYPICAL MANUAL OF THE GEHO HMI PANEL" in chapter "Technical data" for operating the "GEHO HMI PANEL".

Refer to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical data" for operating the GEHO Pump Control System.

7.4.1 Pump operation by local control at the "GEHO HMI PANEL"

The pump can be operated at the "GEHO HMI PANEL" in a "LOCAL" mode = local stand alone operation. The procedures in this manual cover the operation of the pump at the "GEHO HMI PANEL" in its "LOCAL" mode.

7.4.1.1 Selection "LOCAL" or "REMOTE" at the "GEHO HMI PANEL"

Check at the "GEHO HMI PANEL" which actual operation mode is active:

■ "LOCAL" = local operation mode at the "GEHO HMI PANEL".

■ "REMOTE" = remote operation mode at a remote control device.

How to switch from local control (= "LOC.") to remote control (= "REM.") and back:

• Push at the "GEHO HMI PANEL" the field button "LOC.REM." to switch from local control mode to remote control mode and back.

7.4.2 Pump operation by remote control, supplied by others

The "GEHO HMI PANEL" control box has connections for remote control options.

WARNING

Remote control is usually not in the scope of supply of Weir Minerals and has to be provided by the customer.

Refer to the user manual and safety instructions of the supplier of the remote control. Refer for details of the remote control options at the GEHO to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" and document "TYPICAL MANUAL OF THE GEHO HMI PANEL".

Selection "LOCAL" or "REMOTE" at the remote control device

Refer to the user manual and safety instructions of the supplier of the remote control.

Pump operation at the remote control device




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7.5 "START" procedures Pos: 17.34 /GEHO/Start and Stop/Common/START + Pre-start procedure_R02 @ 1\mod_1170848561800_31.doc @ 12151 @ 35555533333

7.5.1 Operation definitions

Main motor "RAMP-UP" and "RAMP-DOWN" procedure at the "VFD"

The speed of the electric main motor is controlled by a "VFD" (= "Variable Frequency converter Device"). At this "VFD" the minimum and the maximum speed of the main motor is locked in its pre-settings. These pre-settings can not be overruled at the "GEHO TOUCH PANEL" or at a remote control device.

If the "VFD" is not in the scope of supply of Weir Minerals, then the supplier has to assure the correct settings at the "VFD".

• The "MAXIMUM SPEED LIMITATION" is part of the "Intended use" specification of the pump, to protect the main motor and the transmission parts and the pump against overload.

Refer for details to chapter "Technical data" and to the "GEHO pump identification plate" at the pump.

• The "MINIMUM SPEED LIMITATION" is part of the "RAMP-UP" and "RAMP-DOWN" procedure at the "VFD".

The "MINIMUM SPEED LIMITATION" is NOT part of the "Intended use" specification of the pump, it is a recommendation to avoid pump speeds below this level.

How to operate the main motor "RAMP-UP" and "RAMP-DOWN" procedure at the "GEHO TOUCH PANEL":

• Push the "START" button = the "VFD" performs the "VFD RAMP-UP" procedure, to start the motor from "STOP" to the "MINIMUM SPEED LIMITATION".

• Push the "STOP" button = the "VFD" performs the "VFD RAMP-DOWN" procedure, to stop the motor from the "MINIMUM SPEED LIMITATION" to "STOP".

ATTENTION

The "VFD" performs the "RAMP-UP" and "RAMP-DOWN" procedures independently. These procedures can only be operated by "EMERGENCY STOP" or "START" or "STOP" commands, these procedures can not be influenced by other operation means.

"ACTUAL SPEED' at the "GEHO TOUCH PANEL"

The "ACTUAL SPEED" displayed at the "GEHO TOUCH PANEL" gives the real speed of the pump ("SPM" = "Strokes Per Minute" = revolutions of the pump crank shaft).

"SPEED-SETPOINT" signal

The "SPEED-SETPOINT" displayed at the "GEHO TOUCH PANEL" indicates the desired speed of the main motor (so it can be different form the "ACTUAL SPEED" value). It can be set with the display buttons "UP", "DOWN" and "ZERO" at the "GEHO TOUCH PANEL".

ATTENTION

The "VFD" will ignore: • a "SPEED SETPOINT" higher then the "MAXIMUM SPEED LIMITATION" set at the

"VDF", • a "SPEED SETPOINT" lower then the "MINIMUM SPEED LIMITATION" set at the

"VDF".

"ZERO" button at the "GEHO TOUCH PANEL"

• If the "SPEED-SETPOINT" at the "GEHO TOUCH PANEL" is set to zero, and the "MINIMUM SPEED LIMITATION" at the "VFD" is also set to zero, then the motor and the pump remain in a "stand-by idle status". (= "0 SPM" at the "GEHO TOUCH PANEL" = zero "Strokes Per Minute" = zero revolutions per minute of the pump crank shaft.)


7.10 201150-IOM-EN-R03

7.5.2 "PRE-START" check list

DANGER

If the pump is operated, then the operator has to assure: 1 that the pump can run safely, 2 that the pump can deliver its flow safely, 3 that the pump will not run dry.

• NEVER start the main motor, if one of the checks below fails.

Control systems:

1 Check the air supply and the air pressure.

Refer to document "UTILITY CONSUMPTION LIST" for details about quality and quantity and pressure.

2 Check the pre-charge pressure of the diaphragm pulsation dampeners. Propelling liquid section: 3 Check that the propelling liquid sections are filled. 4 Check that the propelling liquid sections are de-aerated. 5 Check that the propelling liquid de-aeration valves are closed.

Slurry section at the pump:

6 Check that the slurry end is filled and de-aerated. Slurry lines of the pump system: 7 Check that all slurry line flushing valves are closed. 8 Check that all slurry line drain valves are closed. 9 Check that the slurry line main suction valve is open. 10 Check that the slurry line main discharge valve is open.

7.5.3 "PRE-START" working with the GEHO and "VFD" main power switch "ON"

1 Check that the pump "EMERGENCY STOP SYSTEM" is operational. 2 Check that the main power switch of the GEHO pump system is switched "ON". 3 Switch "ON" the main power switches of the "VFD" (Variable Frequency Drive) and the main motor.


201150-IOM-EN-R03 7.11

7.5.4 "PRE-START" procedure, if "LOCAL" operated

Use this procedure only, if the pump system is ready to operate. 1 Push the "START/STOP" button at the "GEHO TOUCH PANEL". 2 Push the "PRE-START" button at the "GEHO TOUCH PANEL".

The electrical "PRE-START" procedure performs: 2.1 Start of all auxiliary systems. 2.2 Check of the electrical "PRE-START" conditions.

The main motor can only start, if all pre-conditions are fulfilled.

Refer for details to the document "LOGIC DIAGRAM" in chapter "Electrical information", and the document "DESCRIPTION OF THE PUMP CONTROL SYSTEM in chapter "Technical data".

2.3 During the "PRE-START" procedure the "COMMON ALARM" lamp flashes. 2.4 If the "PRE-START" procedure is finished successfully and the pump is ready to run, then:

• the "COMMON ALARM" lamp stops flashing, • "PUMP READY TO RUN" is displayed at the "GEHO TOUCH PANEL". Go to the "START" procedure.

2.5 If the "PRE-START" procedure fails for the pump is not ready to run, then: • the "COMMON ALARM" lamp keeps flashing, • the concerned alarms are displayed at the panel. Check the reasons for the alarms and solve the causes. Repeat this "PRE-START" procedure.

7.5.5 "PRE-START" procedure, if "REMOTE" operated


During "REMOTE" operation, the "GEHO TOUCH PANEL" displays: ■ "REMOTE" = remote operation mode at a remote control device.


7.12 201150-IOM-EN-R03

7.5.6 "START" procedure, if "LOCAL" operated

1 Check the "SPEED-SETPOINT" at the "GEHO TOUCH PANEL". Push the button "ANALOG VALUES" to check the "SPEED SETPOINT".

2 Change the "SPEED SETPOINT" value with the buttons "UP" and "DOWN". 3 Push the "START" button at the "GEHO TOUCH PANEL". 4 The "VFD" starts the "RAMP-UP" procedure,

the main motor starts and runs up first phase to the value of the "MINIMUM SPEED LIMITATION" at the VFD, second phase to value of the "SPEED-SETPOINT" speed.

4.1 Push the button "ANALOG VALUES" to check the "SPEED SETPOINT" and the "ACTUAL SPEED". 4.2 If at the "VFD" the "MINIMUM SPEED LIMITATION" is set to zero,

then the motor will only speed up by pushing the "UP" button. Changing the speed of the pump: 1 Change the "SPEED SETPOINT":

Push the "UP" button or "DOWN" button at the "GEHO TOUCH PANEL".

ATTENTION

The "Variable Frequency converter Device" (= "VFD") will ignore: • A "SPEED SETPOINT" higher then the "MAXIMUM SPEED LIMITATION" set at the

"VDF". • A "SPEED SETPOINT" lower then the "MINIMUM SPEED LIMITATION" set at the

"VDF". 2 Check that the "ACTUAL SPEED" follows the "SPEED SETPOINT" value. Pos: 17.35 /GEHO/Start and Stop/Common/START, remote control @ 1\mod_1170863453339_31.doc @ 12161 @

7.5.7 "START" procedure, if "REMOTE" operated

INFORMATION

If applicable, refer to the manual of the supplier of the remote control system.

Refer also to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical data" for details about remote control.

• Push the button "LOC.REM." to switch from local control to remote control and back.

During "REMOTE" operation, the "GEHO TOUCH PANEL" displays: ■ "REMOTE" = remote operation mode at a remote control device. The "ACTUAL SPEED" of the pump.



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7.6 "STOP" procedures Pos: 17.38 /GEHO/Heading/H3/#.#.# Emergency stop @ 1\mod_1166006853944_31.doc @ 9285 @

7.6.1 "EMERGENCY STOP" procedure Pos: 17.39 /GEHO/Start and Stop/Common/Emergency stop @ 1\mod_1166005615179_31.doc @ 9281 @

"CE" conformity

DANGER

An emergency shut down button has to be present within a short distance of the pump.

DANGER

When failing to install and maintain the "EMERGENCY STOP" button equipment in accordance with this manual, then the installation is no longer in "CE"-conformity (as defined by the European "Directive on machinery 98/37/EC and 2006/42/EC") and thus results in:


Refer to chapter "Safety equipment" for details about requirements of the "EMERGENCY STOP" system.

"EMERGENCY STOP" signal

In case of an "EMERGENCY STOP":

DANGER

• The "EMERGENCY STOP" overrules all other operation options.

• The electrical supply of all pump auxiliary motors will shut-down immediately.

• The "VFD" (="Variable Frequency converter Device") stops the main motor.

Refer for details to the manual of the VFD system in "Appendix: Catalogue information".

• The pump system (motor + transmission + pump) will without power supply stop (coast to rest, wasting its dynamic energy).

• The pump control system (with the "GEHO TOUCH PANEL") remains operational, but as long as the "EMERGENCY STOP" status remains, all operation options of the motors are blocked.

DANGER

After an "EMERGENCY STOP":

• Refer to the manual of the "EMERGENCY STOP" system of the supplier of that system for procedures how to handle an "EMERGENCY STOP" and how to start again.

• Make sure, that the reason for the "EMERGENCY STOP" is attended and solved, before starting the pump again.

After an "EMERGENCY STOP", the pump system is ready for a regular "PRE-START" procedure. Pos: 17.40 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


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7.6.2 "STOP" procedure, if "LOCAL" operated

ATTENTION

This "STOP" button procedure is preferred:

• For longer operation interruptions, to switch off all auxiliary systems of the pump.

• For a normal stop, that does not require an "EMERGENCY STOP".

If the pump is stopped with the "STOP" button, then start the pump with the "PRE-START" button, to start all auxiliary systems.

To stop the pump: 1 If the pump runs in the "REMOTE" mode,

to switch the control in the "LOCAL" mode, then push the "LOCAL" or "REMOTE" button at the "GEHO TOUCH PANEL".

2 Push the "STOP" or "STOP" button at the "GEHO TOUCH PANEL". 3 Push the "STOP" button at the "GEHO TOUCH PANEL".

The automatic "STOP" program contains: 3.1 The "VFD" stops the main motor with the "RAMP-DOWN" procedure. 3.2 All auxiliary systems will stop. Pos: 17.42 /GEHO/Start and Stop/Common/### STOP by remote control @ 1\mod_1170863607721_31.doc @ 12166 @

7.6.3 "STOP" procedure, if "REMOTE" operated

INFORMATION

If applicable, refer to the user manual and safety instructions of the supplier of the remote control.

• Push at the "GEHO TOUCH PANEL" the button "LOC.REM." to switch from "LOCAL" control to "REMOTE" control and back.

Refer also to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical data" for details about the remote control.



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7.6.4 "STOP" procedure for flushing Pos: 17.45 /GEHO/Start and Stop/Flushing slurry section, general @ 1\mod_1169569488886_31.doc @ 11969 @ 4

7.6.4.1 Flushing the slurry section, general recommendations

ATTENTION

• Flush the slurry section, if the pump may get out of operation for a longer time.

If the pump system stops for a longer period, then:

– the slurry may get clogged, so starting up may need more time and energy and cause troubles.

– the slurry may get acid, so this may result to damage to the inner surfaces of the pump slurry section.

The decision to flush depends on:

– the quality of the slurry,

– the period of still stand,

– general experience and operating and precaution arguments.

The flushing connections are not in the scope of supply of this pump system.

Refer to drawing "FLUSHING/FILLING/DRAIN CONNECTIONS" in chapter "Technical data" for details, how this may be arranged on the pump system. Pos: 17.46 /GEHO/Start and Stop/Common/STOP, flushing procedure @ 1\mod_1170094728267_31.doc @ 12072 @ 4

7.6.4.2 Flushing the slurry section procedure

1 Keep the pump system running at minimum speed. 2 Flush the pump with clean water for at least 5 minutes. 3 Stop the pump at the GEHO touch panel.

Refer for details to documents "DESCRIPTION OF THE PUMP CONTROL SYSTEM" and "TYPICAL MANUAL OF THE GEHO TOUCH PANEL".

The slurry section of the pump remains filled with clean flush water. At the end of the flushing procedure, the pump is in the right position for starting.

ATTENTION

Keep the pump system in the ready-to-start modus:

• DO NOT switch off the air pressure. This prevents that the propelling liquid sections get discharged.

• DO NOT switch off the electric power supply.



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DANGER

Before working on the pump system, it is necessary to:

• Flush the pump slurry section with clean water.

• Stop the pump system.

• De-pressurize the slurry section.

• De-pressurize the pump auxiliary systems.

• Switch off all power supply.

• Lock all pump system main switches, to prevent un-intentional starting.

7.6.5.1 Pump, switch off procedure

1 Flush the pump slurry section with clean water for at least 5 minutes.

Refer to chapter "Stop for flushing procedure".

2 Push the "STOP" button at the "GEHO TOUCH PANEL".

Refer for details to document "DESCRIPTION OF THE PUMP CONTROL SYSTEM" in chapter "Technical Data".

During this stop the slurry section of the pump remains filled with clean flush water, the pump remains ready to re-start.

7.6.5.2 Slurry section, de-pressurize and drain procedure

for working on the valves and pump diaphragm and piping.

ATTENTION

• AVOID to disconnect or switch off the air pressure at this phase of the procedure.

This prevents that the propelling liquid sections get discharged. 1 Close the main valve in the discharge lines. 2 Close the main valve in the suction lines. 3 Open the drain plug in the discharge line. 4 Open the drain plug of the slurry section. 5 Open the drain plug of the suction section. 6 If applicable, then depressurize the discharge pulsation dampener. 7 If applicable, then depressurize the suction pulsation dampener.

7.6.5.3 De-pressurize the pump auxiliary systems.

1 Safety relief valve: Open the drain valve at the relief valve, to relief the liquid pressure at the connecting piping between the propelling liquid chambers and the safety relief valve.

2 Propelling liquid system: Open the 3-way-drain valve at the pressure accumulator, to relief the pressure at the connecting piping of the propelling liquid system.


201150-IOM-EN-R03 7.17

7.6.5.4 Stop the air supply

To disconnect or switch off the air pressure, obey the procedure below.

ATTENTION

• Stop the air only with this procedure. This procedure prevents that the propelling liquid sections get discharged.

De-pressurize the slurry suction line and slurry discharge line at the pump(s):

1 Close the main suction valve in the slurry line. 2 Close the main discharge valves in the slurry line. 3 Open the drain valve in the slurry discharge line. 4 Stop and dis-connect the air supply.

7.6.5.5 Switch off the electric main supply to all related parts

DANGER

1 Switch off all electric main switches for the pump system and the main motor and its "VFD".

2 Lock all electric main switches, to prevent un-intentional starting. Pos: 17.50 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


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7.6.6 "STOP" procedure for "EXTENDED SHUT-DOWN"

This procedure is recommended to preserve a pump for a temporary "EXTENDED SHUT-DOWN" for more then 3 weeks up to 6 months. If a pump should be shut-down or de-commissioned for a period longer then 6 months, then contact in advance the service department of Weir Netherlands b.v.

ATTENTION

• Contact the OEM suppliers for their instructions for the drive components (like motor, gearbox, V-belt, coupling, transformer).

Recommendation for the crankshaft turning intervals: 1 Immediately or short after the stop of pumping slurry:

Flush the pump with clean water for at least 5 minutes at minimum speed. Refer to the flushing procedure.

2 Repeat this every 4 weeks. If possible, then run the pump with the motor power. If not possible, then turn the crankshaft with help of the manual provisions.

Preservation procedure

DANGER

Do this work only during shut-down and lock-out of the pump (refer to chapter "Maintenance safety instructions").

1 Add an anti-corrosion additive agent to the lubrication oil, fill it into the pump power end oil sump, to achieve an inside preservation of the pump power end components, during running of the lubrication pump. We recommend "Shell VSI 8235" for a use at 2% volume solution (avoid higher concentrations).

Crankshaft turning procedure by the motor

1 If installed, then switch on the oil heaters, at least 10 minutes before starting. 2 Refer to the according chapters for the "PRE-START checklist" and to start the lubrication pump. 3 Flush the pump with clean water for at least 5 minutes at minimum speed.

Refer to the flushing procedure.

Crankshaft turning procedure by manual provisions

Refer to the chapter "Special tools", "Socket wrench".

1 Check that the pump crankshaft can turn freely and pump water, without pressurizing the discharge line (with an open flushing valve in the discharge line).

2 If installed, then switch on the oil heaters, at least 10 minutes before start-up. 3 Use the normal procedures to start the lubrication pump. 4 Run the lubrication pump for at least 5 minutes.

Check at an open side cover, that the bearings and crosshead are lubricated. 5 Turn the crankshaft around (minimum 2 complete revolutions), by the manual provisions, according to

chapter "Socket wrench". 6 Stop the lubrication pump.

Preservation of the pump parts

1 Shut-down and lock-out the pump. 2 Coat the machined surfaces with a preservation agent.

We recommend "Cortec VCI-369D" (or "Castrol Rustillo DWX-32" or equal). "Cortec VCI-369D" is compatible with the recommended lubrication oil, so it does not require to be removed, before putting the pump into operation again.

3 Refer to chapter "2/2 way valves: inspection and preservation" for the preservation of these valves. 4 Replace the air filter at the power end by a plug, to avoid loss of the agent by evaporation. 5 Clean the pump at the outside. 6 Before the next start of the pump, a de-aeration of the propelling liquid system and a priming of the

pump are required. Refer to the according procedures.


Maintenance

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8.1 Maintenance safety instructions

ATTENTION

• Do not hesitate to contact the Service Department of Weir Minerals, if problems occur during maintenance or repair activities.

DANGER

• Strictly obey to all instructions as given in the chapter "Safety" of this manual.

The correct working sequence along with the data in this manual is of the utmost importance for safe operation and handling.

• Only authorized and properly trained people are allowed to do maintenance work with the pumps.

• Only use original and undamaged GEHO parts.

DANGER

MAINTENANCE CHECKPOINTS during operation, with running pump:

• Prevent contact with moving parts and hot parts and parts under pressure.

DANGER

MAINTENANCE CHECKPOINTS during shut-down and lock-out of the pump: For safe working on the pump it is essential, that the installation is locked out from all energy sources.

• For stopping the pump, refer to chapter "STOP for maintenance procedure" (including de-pressurizing and draining the slurry section and dampeners).

• Lock-out power the supply to the main motor and its VFD "Variable Frequency converter Device".

• Lock-out power the supply to the lubrication oil motor.

• Lock-out power the supply to the propelling liquid motor.

• Lock-out power the supply to all auxiliary motor(s) of the gearbox (if applicable).

• Lock-out power the supply to the GEHO HMI TOUCH PANEL.

• Lock pump isolation valves in closed position.

• Disconnect the air supply only, when working on the air-actuated valves.

INFORMATION

The below mentioned maintenance checkpoints are rough guidelines. The real maintenance intervals have to be determined based on actual performance during operation. This especially valid for the high wear parts. Inspection of these parts should take place at least monthly until the real wear live has been determined.

INFORMATION

Refer to chapter "Assembly and disassembly" for maintenance and (dis)assembling of valves, valve seats, diaphragms, piston, cylinder and cylinder liner.

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Maintenance

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8.2 Maintenance: log book

ATTENTION

• Use a log book, to achieve a proper operation and maintenance history. As part of a plant quality assurance plan, we recommend to use a log book with operation and maintenance checklist sheets. Copies of the following pages can be used to achieve this.

8.3 Maintenance: references

Refer for the allowed operation characteristics of the pump to chapter "Technical data".

Refer for the location and technical data of the maintenance checkpoints also to:

• 814.201150.00 "DIMENSIONED OUTLINE DRAWING",

• 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST",

• 814.201150.03 "P&I DIAGRAM TZPM 2000",

• Chapter "Appendix: Parts - Lists and drawings (pump section)".

Refer for operation of the "GEHO TOUCH PANEL " to: chapter "Technical data":

• 814.201150.20 "DESCRIPTION OF THE PUMP CONTROL SYSTEM",

• 814.200000.22 "TYPICAL MANUAL OF THE GEHO TOUCH PANEL TZPM", chapter "Appendix: Electrical information":

• Electric drawings: S.814.201150.05 + S.814.201150.06 + S.814.201150.07 + S.814.201150.09 .

8.4 Maintenance: checkpoints of the pump drive components

Refer to chapter “Appendix: Catalog information”, for documents about the pump components and their maintenance. References for the main components:

MAINTENANCE CHECKPOINTS Interval Location Checkpoint Check / Action All intervals

Drive unit: T.814.201150.16

Electric main motor

814.201150.30 = T.814.201150.16 -004

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Electric main motor".

Gearbox + cooling + oil-filters

814.201150.31 = T.814.201150.16 -001

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Gearbox".

Coupling motor / gearbox

814.201150.32 = T.814.201150.16 -002

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Coupling".

Coupling pump / gearbox

814.201150.33 = T.814.201150.16 -003

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Coupling".

Frequency converter

814.201150.38 = T.814.201150.16 -005

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Frequency converter".

Transformer 814.201150.39 = T.814.201150.16 -006

Check the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Transformer".

Maintenance

201150-IOM-EN-R03 8.3

8.5 Maintenance: intervals

Log.nr. Date Pump number Operation hours Performed by Done Rem.

_ _ . _ _. _ _ _ _ 7201150/ __

Daily check-points

1 General function inspection with a running pump:

CAUTION During operation, with running pump, (to achieve a diagnosis of the pump performance). Refer to chapter "Maintenance safety instructions".

1.1 "GEHO HMI TOUCH PANEL":

Daily check-points

Checkpoint Location Check / Action Done Rem.

Alarm check "GEHO HMI TOUCH PANEL" T.814.201150.42 -001

Push the alarm button for a manual check of the alarm light. Refer to 814.200000.22 + 814.201150.20 in chapter "Technical data".

General round check

All units + systems + piping + connections 814.201150.00

Check for changes in running noise. Check for abnormal: temperatures, contamination, noise, vibrations. Check for leaks of air, oil, slurry.

General performance check

"GEHO HMI TOUCH PANEL" Check all performance data at the "GEHO HMI TOUCH PANEL". Refer to 814.200000.22 + 814.201150.20 in chapter "Technical data".

Slurry flow "GEHO HMI TOUCH PANEL"

Check for (not) correct relation between the pump speed and the slurry flow rate. Refer to 814.200000.22 + 814.201150.20 in chapter "Technical data".

Maintenance

8.4 201150-IOM-EN-R03

1.2 General status + performance:

Daily check-points


General round check

814.201347.00 All units + systems + piping + connections

Check for changes in running noise. Check for abnormal: temperatures, contamination, vibrations, filters. Check for leaks of air, oil, slurry.

"Discharge working pressure": pressure transmitter, connected to the top of the discharge pulsation dampener, displayed at the "GEHO HMI TOUCH PANEL".

pressure transmitter T.855.000.089 - 002=PT3 814.200000.22 + 814.201150.20

Check for no alarms at the "GEHO HMI TOUCH PANEL". Check the trend graph at the "GEHO HMI TOUCH PANEL". Check the slurry discharge pressure. Refer for the allowed pressure to chapter "TECHNICAL DATA" and to document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

"Discharge working pressure": pressure gauge, connected to the top of the discharge pulsation dampener

pressure gauge T.818.080.195 - 011 (2x)

Check that the pressure is corresponding with the pressure, given by the pressure transmitter, mentioned above.

"Suction working pressure": pressure transmitter, connected to the top of the suction air vessel, displayed at the "GEHO HMI TOUCH PANEL".

pressure transmitter T.851.000.392 - 021 =PT8 814.200000.22 + 814.201150.20

Check for no alarms at the "GEHO HMI TOUCH PANEL". Check the data at the "GEHO HMI TOUCH PANEL". Check the slurry suction pressure. Refer for the allowed suction pressure (maximum and minimum NPSH required) to chapter "Technical data". Refer for the minimum suction pressure alarm to the SETPOINT of the pressure transmitter at the suction air vessel, as listed in document 814.201150.02 INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

"Suction working pressure": pressure gauge, connected to the top of the suction air vessel.

pressure gauge T.851.000.392 - 014 =PI8

Check that the pressure is corresponding with the pressure, given by the pressure transmitter, mentioned above.

Maintenance

201150-IOM-EN-R03 8.5

1.3 Air supply (for the solenoid valves of the "Propelling liquid unit")

T.857.000.208 -065

Daily check-points


Air supply: connection

NOT IN THE SCOPE OF SUPPLY.

Check the air supply. Refer for the allowed pressure and quality to document 814.201150.19 "UTILITY CONSUMPTION LIST" in chapter "Technical Data".

Check the air supply. Check for leaks. Check for abnormal: noise, temperatures, vibrations, filter contamination. If applicable and necessary: • Drain the filter. • Replace the filter. • Add suitable oil.

Air supply: pressure transmitter

T.855.000.089 -001=PT7 Check for no alarms at the "GEHO HMI TOUCH PANEL". Refer for the allowed pressure to document 814.201150.19 "UTILITY CONSUMPTION LIST". in chapter "Technical Data".

Air supply: pressure gauge

T.857.000.208 - 065 =PI7 Check that the pressure is corresponding with the pressure, given by the air pressure transmitter, mentioned above.

1.4 "DRIVE UNIT": T.814.201150.16

Daily check-points


Electric main motor

814.201150.30 = T.814.201150.16 -004

Check the instructions of the supplier.

Gearbox 814.201150.31 = T.814.201150.16 -001

Check for abnormal: noise, vibrations, temperatures, contamination.

Gearbox oil cooling system

814.201150.31 = T.814.201150.16 -001

Check the temperature gauge. Check for leaks. Check the filter(s). Check for abnormal: noise, vibrations, temperatures, contamination.

Coupling pump-shaft / gearbox

814.201150.33 = T.814.201150.16 -003

Check for changes in the running noise. Check for oil leakage under the safety cover. This coupling is filed with oil, lost of oil causes faster wear of its teeth.

Maintenance

8.6 201150-IOM-EN-R03

1.5 "LUBRICATION UNIT": T.828.900.362

Daily check-points


Lubrication oil: level in the sump

T.845.000.482 -138 Check the level at oil sight glass.

Pressure gauge in the oil discharge line

T.828.900.362 -015 Check the pressure.

Oil flow sensor T.828.900.362 -100 Check that the low sensor indicator LED’s status is green. Check for no alarms at the "GEHO HMI TOUCH PANEL".

Oil filter in the discharge line

T.828.900.362 -020 T.828.900.362 -021

Check visual the clogging indicator, it should be green. If necessary, then replace during shut-down the filter element. Refer to the related chapter.

1.6 "PROPELLING LIQUID UNIT": T.857.000.208

Daily check-points


Propelling liquid level in the tank

T.857.000.208 -152 Check the level at the oil sight glass.

Flow sensor T.857.000.208 -100 Flow sensor indicator LED status is green.

Discharge filter T.857.000.208 -020 T.857.000.208 -021

Check visual the clogging indicator, it should be green. If necessary, then replace during shut-down the filter. Refer to the related chapter.

Pressure gauge

T.857.000.208 -060 Check the pressure. Refer for the allowable pressure to the document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

Pressure transmitter

T.855.000.089 - 003 (1x)

No alarms at the "GEHO HMI TOUCH PANEL". Refer to the documents 814.200000.22 + 814.201150.20. Refer for the allowable pressure to the document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

Maintenance

201150-IOM-EN-R03 8.7

De-aeration valves of propelling liquid at each diaphragm house

T.832.000.250 -070 (3x) T.828.900.292 -006 =FI 6A+6B+6C

Vent each diaphragm chamber, until no air is released. Watch at the transparent tube for air bubbles. During the start-up period, some air can appear. Air bubbles after the start-up period may indicate leakage in the propelling liquid system.

De-aeration vent of propelling liquid at the pressure limitation unit

T.853.000.233 -024 (1x) T.828.900.292 -006

Open the needle valve, to vent the safety valve, until no air is released. Watch at the transparent tube for air bubbles. During the start-up period, some air can appear. Air bubbles after the start-up period may indicate leakage in the propelling liquid system.

Propelling liquid

SV = air-solenoid 3/2 way valves: T.857.000.208 - 050+055

Check for no air leakage.

filling valves + outlet valves + cylinder flush valve

HV = hydraulic 2/2 way valves: T.853.000.068 = T.853.000.240 -001 T.853.000.110 = T.853.000.240 -014

Check for no air or oil leakage.

Sequence for actuation of the filling valves + outlet valves

Refer for the function details to chapter "Start-up, priming procedure".

Maximum once per 5 minutes. If available/applicable: Check at the "GEHO HMI TOUCH PANEL" the history of the propelling liquid valves actuation frequency. Refer to the documents 814.200000.22 + 814.201150.20 in chapter "Technical Data".

If the frequency is increasing, then search for causes. Like leakage at the piping or wear at the piston seals, or a left open vent valve.

Maintenance

8.8 201150-IOM-EN-R03

1.7 Slurry section:

Daily check-points


Slurry valves: discharge valves + suction valves

T.820.201150 -025 = T.831.000.472 -026 = T.831.000.441

No abnormal or extreme noise inside the valve housings.

Covers of discharge valve housings + suction valve housings + pump diaphragm housings

T.820.201150 -025 = T.831.000.472 -026 = T.831.000.441 -030 = T.832.000.250

No leakage of slurry through the covers.

Pulsation dampener diaphragm in the discharge line, housing and cover

T.820.201150 -060 = T.851.000.336

No leakage of slurry through covers.

Suction air vessel in the suction line

T.851.000.392

No leakage of slurry.

8.6 Maintenance: “Hot torque” after initial start-up

Log.nr. Date Pump number Operation hours Performed by Done

Rem.

_ _ . _ _. _ _ _ _ 7201150/ __ Interval 1 Maintenance checkpoints during shut-down

“Hot torque” after initial start-up

DANGER Only during shut-down and lock-out of the pump Refer to chapter "Maintenance safety instructions".


Torque’s of all flanges, covers, bolts and nuts

Re-tighten. For the correct torque, refer to chapter "Tightening torques".

Maintenance

201150-IOM-EN-R03 8.9

8.7 Maintenance: checkpoints 200 hours after initial start-up


_ _ . _ _. _ _ _ _ 7201150/ __ Interval 1 Maintenance checkpoints during operation

200 hours after initial start-up

CAUTION During operation, with running pump. Refer to chapter "Maintenance safety instructions".

1.1 Daily checkpoints

Do the daily checkpoints, with a running pump, before doing the maintenance work checkpoints. (to achieve a diagnosis of the pump performance)

2 Maintenance checkpoints during shut-down

DANGER Only during shut-down and lock-out of the pump. Refer to chapter "Maintenance safety instructions".

2.1 "LUBRICATION UNIT": T.828.900.362 Lubrication oil replacement Refer for details to chapter "Assembly and disassembly".


Lubrication oil sump

Refer for details to chapter "Assembly and dis-assembly", "Lubrication system".

T.845.000.482 -136

Drain the lubrication oil. Clean the oil sump carefully.

T.828.900.362 -010

Inspect the suction strainer (inside the frame). Clean, if necessary.

T.828.900.362 -021 Replace the oil filter element in the discharge line. Refer for specifications to document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

Lubrication oil: quality and quantity

Refer for the correct oil quality and quantity to document 814.201150.19 "UTILITY CONSUMPTION LIST" in chapter "Technical Data".

T.845.000.482 -001 Fill the sump with new oil. T.845.000.482 -138 Check oil level at the oil sight glass. 2.2 "DRIVE UNIT": T.814.201150.16


Gearbox oil 814.201150.31 = T.814.201150.16 -001

Replace the oil. Refer to "Catalogue information", "Gearbox" for manual instructions of the manufacturer.

Refer for the correct oil quality and quantity to document 814.201150.19 "UTILITY CONSUMPTION LIST". in chapter "Technical Data".

Gearbox: oil filter Replace the filter element. Gearbox:

oil cooling/filter circulation system

814.201150.31 = T.814.201150.16 -001

Check the oil level at the oil dipstick, immediately after start-up, to ensure, that the circulation system is filled properly.

Maintenance

8.10 201150-IOM-EN-R03

8.8 Maintenance: interval checkpoints


_ _ . _ _. _ _ _ _ 7201150/ __ Interval legend 2000 = After each operating period of 2000 working hours,

or after 3 months of operation, whatever comes first. 4000 = After each operating period of 4000 working hours,

or after 6 months of operation, whatever comes first. 8000 = After each operating period of 8000 working hours,

or after 12 months of operation, whatever comes first.

The maintenance instructions of the suppliers are leading.

The exact maintenance interval checkpoints of all delivered pump components, particularly the drive components, are listed in the suppliers documentation which, if present, is included in chapter "Catalogue information". The following maintenance interval checkpoints are chosen for provisional orientation.

1 General function inspection of a running pump

Done Rem.

CAUTION During operation, while running. Refer to chapter "Maintenance Safety Instructions".

1.1 Daily checkpoints

2000 Do the daily checkpoints, with a running pump, before doing the maintenance work checkpoints (to achieve a diagnosis of the pump performance).

2. Maintenance checkpoints during shut-down

DANGER Only during shut-down and lock-out of the pump. Refer to chapter "Maintenance safety instructions".

2.1 Lubrication oil sample

To achieve reliable and economical performance of the pump, we recommend regular oil quality checks by an oil laboratory. Oil change intervals depend on the operation conditions and oil quality and oil quantity. We recommend for normal conditions an oil check interval of 2000 working hours or 3 month. Refer for the procedure to document MI.093701 "MAINTENANCE INSTRUCTION FOR LUBRICATION OIL MONITORING AND SAMPLING" in chapter "Technical Data".

Interval Checkpoint Location Check / Action Done Rem.

2000 Frame unit: lubrication oil sump lubrication system

814.201150.31 = T.814.201150.16 -001

Do the oil quality laboratory check. Take an oil sample at the probe plug between the pump and the filter. Send it in to the oil supplier laboratory, for a recommendation of a time schedule for replacing the oil.

Depending on the result, if necessary: Replace the oil and the oil filters. Refer for instructions and details to the table for "200 hours interval".

Maintenance

201150-IOM-EN-R03 8.11

2.2 "DRIVE UNIT": T.814.201150.16


Gearbox + cooling system

814.201150.31 = T.814.201150.16 -001

Refer to the instructions of the supplier. Refer to “Appendix: Catalogue information”, "Drive unit", "Gearbox".

2000 Gearbox: oil Do the oil quality laboratory check. Take an oil sample and send it in to the oil supplier laboratory, for a recommendation of a time schedule for replacing the oil.

Depending on the result, if necessary: Replace the oil and the oil filters. Replace the oil filter elements. Refer for instructions and details to the table for the "200 hours interval".

2000 Gearbox

labyrinth seal at the output shaft and/or the input shaft

Grease at the grease nipples the seals of the output shaft and/or the input shaft. Refer to the manual of the gearbox, to the related sticker on the gearbox and to the lay-out drawing of the gearbox.

4000 Gearbox Clean the breather/air-vent.

8000 Coupling motor / gearbox

814.201150.32 = T.814.201150.16 -002

Refer to the instructions of the supplier. Refer to “Catalog information”, "Drive unit", "Coupling".

8000 Coupling motor / gearbox

Check the coupling alignment. Refer for details to chapter "Transport and installation", "Drive unit".

Re-align, if necessary.

8000 Coupling pump / gearbox

814.201150.33 = T.814.201150.16 -003

Refer to the instructions of the supplier. Refer to “Catalog information”, "Drive unit", "Coupling".

Check the coupling alignment. Refer for details to chapter "Transport and installation", "Drive unit".

Re-align, if necessary.

8000 Replace the oil in the ZAPEX coupling. Refer for details to chapter "Transport and installation", "Drive unit". Refer to "Catalogue information", "Drive unit" for manual instructions of the manufacturer. Refer for the correct oil quality and quantity to document 814.201347.19 "UTILITY CONSUMPTION LIST" in chapter "Technical Data".

Maintenance

8.12 201150-IOM-EN-R03

Motor 814.201150.30 = T.814.201150.16 -004

Refer to the instructions of the supplier.

Frequency converter (VFD = variable frequency converter device)

814.201347.38 = T.814.201347.16 -005


Transformer 814.201347.39 = T.814.201347.16 -006


Air supply NOT IN THE SCOPE OF SUPPLY OF "WEIR MINERALS NETHERLANDS B.V."

Refer to the instructions of the supplier. Refer for the details about the air supply to 814.201347.19 "UTILITY CONSUMPTION LIST" in chapter "Technical Data".

2.3 "FRAME UNIT": T.845.000.482


4000 Check the drive shaft seals

T.845.000.482 - 118 Visual outside inspection: No oil should leak at the outside end of the pump drive shaft. Record sign’s of wear damages. If necessary, contact the Service Department of "WEIR MINERALS NETHERLANDS B.V."

4000 Frame unit T.845.000.482-019 Remove the frame main cover and the frame inspection covers.

Check the pump crank shaft. Check the moving parts.

T.845.000.482 - 008 Visual inside inspection: Record sign’s of wear or damages or corrosion at the crankshaft +crossheads + guides + bearings. If necessary, contact the Service Department of "WEIR MINERALS NETHERLANDS B.V."

Crosshead rod seals in the dust cover

T.845.000.482 See, detail X: -080 -081

No oil leakage between the crankshaft frame and the piston chamber. If necessary, then contact the Service Department of Weir Minerals Netherlands b.v.

8000 Piston clamping piece

T.845.000.482 -046 Check the required tightening torque, according to chapter "Tightening torques". Re-tighten, if required.

8000 Piston nut T.835.000.190 -010 Check the required tightening torque, according to chapter "Tightening torques". Re-tighten, if required.

8000 Air vent/filter of the oil sump

T.845.000.482 - 140 Replace the air vent/filter. Refer for specifications to the document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

Maintenance

201150-IOM-EN-R03 8.13

2.4 "PISTON UNIT": T.835.000.200


4000 Piston seals

Check at the "GEHO HMI TOUCH PANEL" in the "TRENDS GRAPH" menu the filling frequency. Refer to the document 814.200000.22 in chapter "Technical Data". A high filling frequency can indicate leakage at the piston seals.

"SET OF ROOF SHAPED RINGS" (chevrons)

T.835.000.190 -020 -021

Visual inspection: Check for no propelling liquid leakage from the pump cylinder to the piston chamber.

Replace, if required. Refer for instructions and details to chapter "Assembly and disassembly", "Piston unit". If necessary, then contact the Service Department of "WEIR MINERALS NETHERLANDS B.V."

8000 Cylinder liner T.835.000.190-002 Inspect the surface of the cylinder liner. Replace, if required. Refer for instructions and details to chapter "Assembly and disassembly", "Piston unit".

8000 Piston rod nut T.835.000.190 -010 (1x)

Check the required tightening torque, according to chapter "Tightening torques". Re-tighten, if required.

Maintenance

8.14 201150-IOM-EN-R03

2.5 "PROPELLING LIQUID UNIT": T.857.000.208


4000 Propelling liquid oil tank

T.857.000.208 -150 Do the oil quality laboratory check. Take an oil sample and send it in to the oil supplier laboratory, for a recommendation of a time schedule for replacing the oil.

Depending on the result, if necessary: Replace the oil. Replace the oil filters. Refer for instructions and details to chapter "Assembly and disassembly", "Propelling liquid system".

8000 Air vent filter of the propelling liquid unit, located on the cover, above the cylinders

T.845.000.482 - 140 (1x)

Replace the air vent/filter. Refer for specifications to document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

8000 Propelling liquid accumulator

T.857.000.208 -040 Check the pre-charge pressure. Refer for specifications to 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data". Refer for instructions and details to chapter "Pre-charging an accumulator with nitrogen".

8000 Propelling liquid: filling valves + outlet valves + supply valves + cylinder flush valves

SV = air-solenoid 3/2 way valves: T.857.000.208 -070 = T.853.000.240 -001+014

Inspect the functions. Replace parts, if there is any leakage between the valves and valves seats.

HV = hydraulic 2/2 way valves: T.857.000.208 -070 = T.853.000.240 - 002 = valve seat - 019 = valve seat

HV = hydraulic 2/2 way oil valves spindle / seal guide

spindle / seal guide T.853.000.240 -001 = T.853.000.068 T.853.000.240 -014 = T.853.000.110

Refer to chapter "2/2 way valves: inspection and preservation".

Maintenance

201150-IOM-EN-R03 8.15

2.6 Slurry section: T.820.201150


4000 Covers of the discharge valve housings,

T.820.201150 -025 = T.831.000.472

No leakage of slurry through cover seals or flanges.

the suction valve housings,

-026 = T.831.000.441

the pump diaphragm housings

-030 =T.832.000.250

8000 Slurry chambers: discharge valves, suction valves, diaphragm chambers, discharge manifolds, suction manifolds, pulsation dampeners

T.831.000.472 (3x) T.831.000.441 (3x) T.832.000.250 (3x)

Carefully clean and inspect the slurry chambers. Watch for internal wear or cracks during valve maintenance intervals. In high wear cases, check the wall thickness and record cavies. Contact for spare parts in time the Service Department of "WEIR MINERALS NETHERLANDS B.V.".

8000 Pump diaphragm T.832.000.250 -019 (3x)

Replace the pump diaphragms. Refer for instructions and details to chapter "Assembly and disassembly".

2000 Air vessel in the suction line

T.851.000.392 = T.820.201150 -090

Visual outside inspection: Check for no leakage of slurry or air.

2000 Pulsation dampener(s) in the discharge line

T.820.201150 -060 = T.851.000.336

Visual outside inspection: Check for no leakage of slurry.

Check for no leakage of nitrogen at the cover and the connecting parts.

Check the nitrogen precharge pressure (= the pressure at the pressure gauge, with no pressure under the diaphragm). Refer for the related procedure to chapter "Transport and installation". Refer to 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" for the specifications of the pre-charge pressure.

8000 T.851.000.336 -006 Replace the pulsation dampener diaphragm. Refer for instructions and details to chapter "Assembly and disassembly". Pre-charge the pulsation dampener. Refer for the related procedure to chapter "Transport and installation".

Maintenance

8.16 201150-IOM-EN-R03

2.7 General equipment check


4000 Instrumentation Refer to the drawing 814.201150.03 "P&I DIAGRAM"

Clean and calibrate and reset all instrumentation parts. Check the set-points, according to document 814.201150.02 "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical Data".

3. Maintenance checkpoints during the "Start-up" procedure

Refer to the related chapters in this manual.

3.1 Electrical Installation: T.814.201150.42 Function checks, after the previous maintenance work is done:


4000 Initiator union nuts at the diaphragm housings

T.814.201150.42 -005 (3x2 initiators)

Check the initiator union nuts. Refer for details to chapter "Initiator union nuts at the diaphragm housings".

4000 Check the function of the diaphragm stroke control system. Refer for the function details to chapter "Start-up, priming procedure".

T.814.201150.42 -005 (3x2 initiators) T.832.000.250 -015 (3x monitoring rod)

Check the transfer signal of the initiators to the PLC. Check, after one signal from an initiator to the PLC, that the filling valve and the outlet/drain valve are actuated.

4000 Indication of the stroke positions at the "GEHO HMI TOUCH PANEL"

"GEHO HMI TOUCH PANEL" 814.200000.22 + 814.201150.20

Check for correct indication of these actions on the "GEHO HMI TOUCH PANEL" operation screen and events list.

SV = air-solenoid 3/2 way valves: T.857.000.208 - 050+055

4000 Working of the the propelling liquid filling valves + outlet valves + cylinder flush valve

HV = hydraulic 2/2 way valves: T.853.000.240 -001 = T.853.000.068 T.853.000.240 -014 = T.853.000.110

Check the functions, during the priming procedure. Refer for the function details to chapter "Start-up, priming procedure".

Sequence for actuation of the filling valves + outlet valves

Maximum once per 5 minutes. If available/applicable: Check at the "GEHO HMI TOUCH PANEL" the history of the propelling liquid valves actuation frequency.

If the frequency is increasing, than search for causes. Like leakage at the piping, or wear at the piston seals, or a left open vent valve.


Maintenance

201150-IOM-EN-R03 8.17

Pos: 24 /GEHO/Heading/H2/#.# Lubrication system @ 0\mod_1152094184716_31.doc @ 5126 @

8.9 Lubrication system Pos: 25 /GEHO/Maintenance/CAUTION during operation @ 6\mod_1235988366046_31.doc @ 47921 @

CAUTION

MAINTENANCE CHECKPOINTS During operation, with running or stand-by pump.

Refer to chapter "Maintenance safety instructions". Pos: 26 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Lubrication system/### Check the oil level @ 0\mod_1138630463309_31.doc @ 2208 @

8.9.1 Check the oil level

The oil level gauge is located at the side of the power end.

1 Check the lubrication oil level (A) at the oil level gauge.

2 If necessary, then fill up the lubrication oil.

Refer to document "UTILITY CONSUMPTION LIST" in chapter “Technical data”, for the correct oil type quality and the estimated oil quantity.

A

Figure 8.1: Lubrication oil level gauge Pos: 27 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Lubrication system/Change the discharge oil filter/### single oil filter resistance indicator @ 5\mod_1231860867296_31.doc @ 45323 @

8.9.2 Oil filter clogging indicator

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data" and also to chapter "Catalogue information" for the specification of the oil filer and for details and specifications of the filter housing.

8.9.2.1 Visual clogging indicator

The filter housing is equipped with a visual clogging indicator.

Under normal operation conditions, the indicator will show a green display, like shown in the figure.

If the indicator displays red, then the oil filter resistance is too high and needs to be replaced urgently.

Always check for abnormal causes for a clogged filter. Like testing the oil by a laboratory.

Figure 8.2: Oil filter with visual clogging indicator Pos: 28 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Maintenance

8.18 201150-IOM-EN-R03

Pos: 29 /GEHO/Heading/H2/#.# Propelling liquid system @ 0\mod_1152094190955_31.doc @ 5132 @

8.10 Propelling liquid system Pos: 30 /GEHO/Maintenance/CAUTION during operation @ 6\mod_1235988366046_31.doc @ 47921 @

CAUTION


Refer to chapter "Maintenance safety instructions". Pos: 31 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Lubrication system/Change the discharge oil filter/### single oil filter resistance indicator @ 5\mod_1231860867296_31.doc @ 45323 @

8.10.1 Oil filter clogging indicator

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data" and also to chapter "Catalogue information" for the specification of the oil filer and for details and specifications of the filter housing.

8.10.1.1 Visual clogging indicator

The filter housing is equipped with a visual clogging indicator.

Under normal operation conditions, the indicator will show a green display, like shown in the figure.

If the indicator displays red, then the oil filter resistance is too high and needs to be replaced urgently.

Always check for abnormal causes for a clogged filter. Like testing the oil by a laboratory.

Figure 8.3: Oil filter with visual clogging indicator Pos: 32 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Maintenance

201150-IOM-EN-R03 8.19

Pos: 33 /GEHO/Maintenance/Drive unit: gearbox cooling system/## Gearbox maintenance Hansen @ 7\mod_1244639271052_31.doc @ 50761 @

8.11 Gearbox maintenance

CAUTION


Refer to chapter "Maintenance safety instructions".

Refer to chapter "Maintenance" for the frequency of maintenance works.

Refer to chapter "Catalogue Information", "Gearbox" for details about the gearbox maintenance and the grease quality and quantity.

8.11.1 Gearbox: oil filters

Check the visual clogging indicator at the oil filter unit. If the oil filer resistance is too high, than it needs to be replaced urgently. Always check for abnormal causes for a clogged filter. Like testing the oil by a laboratory. Pos: 34 /GEHO/Maintenance/Drive unit: gearbox cooling system/Gearbox double oil filter resistance indicator: foto=HANSEN P4 @ 7\mod_1253871404876_31.doc @ 54693 @

A B

Figure 8.4: Oil filter with clogging indicator



Troubleshooting

201150-IOM-EN-R03 9.1

Pos: 36 /GEHO/Heading/H1/#. Troubleshooting @ 0\mod_1152772213698_31.doc @ 5244 @ 1

9 Troubleshooting Pos: 37 /GEHO/Troubleshooting/Attention - Trouble shooting @ 0\mod_1138615626939_31.doc @ 2139 @

ATTENTION

• Do not hesitate to contact the Weir Minerals Service Department, if problems occur during trouble shooting.

• Refer to chapter “Assembly and disassembly” for instructions of replacing parts.

• If parts of the power end are damaged in such a way that they have to be replaced, then follow instructions in chapter "Assembly and disassembly".

Pos: 38 /GEHO/Troubleshooting/## Trouble shooting table (T)ZPM-gear drive @ 1\mod_1169136012360_31.doc @ 11845 @ 2

9.1 Trouble shooting

POWER END: Lubrication system: Problem/symptom Possible cause Remedy

Low oil level in the power end sump.

See chapter "Maintenance".

Suction filter is clogged. Check the suction filter, if necessary, replace the suction filter.

Discharge filter is clogged, oil circulates inside the pump through its pressure relieve valve, oil and pump get hot .

Check the discharge filter If necessary, then replace the discharge filter.

Suction pipe leakage. Check and tighten connections. Oil pump damaged. Check or replace.

Noise in the lubrication oil pump.

Electric motor oil pump damaged.

Check or replace.

Blocked lubrication discharge line.

Check and clean all lubrication points.

Oil pump is not running. Check electric connections. Oil level power end sump too low.


Suction filter is clogged. Check the suction filter. If necessary, replace the suction filter.

Discharge filter is clogged, oil circulates inside the pump through its pressure relieve valve, oil and pump get hot.

Check the discharge filter. If necessary, then replace the discharge filter.

Suction pipe to oil pump leaks. Tighten connections. Filter valves closed. Open valves. Relief valve in the oil pump clogged.

Check or replace.

Relief valve in the oil pump leaking.

Check or replace.

Flow indicator shows insufficient oil flow (check reading of the oil pressure).

No oil flow at some lubrication points.

Check and clean orifices at the lubrication points.

Troubleshooting

9.2 201150-IOM-EN-R03

Abnormal mechanical noise: Problem/symptom Possible cause Remedy

Malfunction of lubrication system Check the lubrication system. Noise caused by loosened connections and transmitted to power end:

Loose piston.


Loose piston rod/crosshead rod connection.


Loose crosshead rod/on crosshead.

Tighten the crosshead rod.

Incorrect settings/worn parts of crosshead guides, crosshead bearing, connecting rod bearing, crankshaft bearing or other.

Correct setting or replace the worn parts.

Hammering noise synchronous with dead points of the piston stroke.

Power end bearings damaged. Check for temperature rise and replace if necessary.

Problem/symptom Possible cause Remedy Malfunction of lubrication system.

Check the lubrication system.

Power end gears worn/damaged.

See the general note.

Abnormal noise is continuous (frequency more than 500 Hz)

Power end bearings damaged. Check for temperature rise and replace if necessary.

Overheating: Problem/symptom Possible cause Remedy

Malfunction of lubrication system.

Check lubrication system and settings or relief valves, see document "INSTRUMENT AND EQUIPMENT LIST".

Incorrect setting or worn parts.

Correct setting or replace worn parts.

Overheating of the lubrication oil (maximum temperature 80°C).

Gears worn.

Replace.

Malfunction of lubrication system.

Check the lubrication system. Overheating of the crosshead liner.

Damaged running surfaces.

Replace the damaged parts.

Bearings damaged.

Replace the bearings. Overheating of the bearing housing.

Wandered settings or worn bearings.

Correct the settings or replace.

Troubleshooting

201150-IOM-EN-R03 9.3

LIQUID END: Propelling liquid section: Problem/symptom Possible cause Remedy

Leakage in filling pipe. Tighten connections. Leakage of outlet valve. Replace the outlet valve parts. Too low air pressure. See chapter "Maintenance". Filling valve malfunction. Check or replace the valve or the

valve parts. Leakage of the cylinder liner seal. Check and replace, if necessary. Pump diaphragm rupture (this will cause a knocking noise in the pump chamber during the discharge stroke).

Replace the diaphragm.

Air in the propelling liquid chamber. De-aerate the propelling liquid chambers.

Piston seal rings leaking. Replace the seal rings. Leakage in the propelling liquid chamber.

Repair the leakage’s.

Propelling liquid filling: Filling valves too often in operation.

Leaking of the safety valves or valve seats.

Check and replace if necessary.

Leakage of the filling valve. Check and replace the filling valve or seat.

Propelling liquid drain: Outlet valves to often in operating. Rupture diaphragm of the filling valve. Check and replace.

Too low air pressure. Re-adjust the air pressure. Malfunction of the outlet valve. Check and replace if necessary. Leakage of the cylinder liner seals. Check and replace.

Outlet valves to often in operating

Leakage of the piston seals. Check and replace. Leaking of the propelling liquid piping. Tighten the connections. Leaking of the pressure relief valve. Check the set-points and replace the

worn parts. Propelling liquid accumulator not proper pre-charged.

Check the pre-charging.

Drain valve is leaking. Check and replace.

Propelling liquid pump is starting too often.

Damaged running surfaces. Replaced the damaged parts. Diaphragm rupture. "Timing": Problems to synchronize the

movements of each piston stroke with the diaphragm stroke. "Priming": Propelling liquid chamber was not proper filled with oil.

For repair and cleaning, refer to chapter "Assembly and disassembly", "Diaphragm housing unit". To synchronize the movements of each piston stroke with the diaphragm stroke, refer to chapter "Start-up, priming procedure".

Settlement of sediment in the diaphragm housing.

Clean the diaphragm housing. Follow the suitable flushing procedure before the pump stop.

Overfilling by the propelling liquid system.

Check proper functioning of all pump initiators or diaphragm position transmitters with help of a magnet.

Troubleshooting

9.4 201150-IOM-EN-R03

Problem/symptom Possible cause Remedy

Pressure limitation system is leaking. Check the suction filter, system pressure (see chapter "Maintenance") and filter cartridge for damage.

Discharge valve is leaking in such an extent that slurry under pressure flows back (during the suction stroke) via the leaking discharge valve.

Replace the valve and valve seat.

Non-return valve in pipe connection between filling valve and propelling liquid chamber is clogged or damaged.

Check, clean or replace the non-return valve.

The filling valve does not open while there is an electric signal.

Check the diaphragm stroke control system.

Too low air pressure.

Re-adjust the air pressure.

Pneumatic plug valve is closed. Check the globe valve and the air pressure.

Oil level in the propelling liquid tank too low.

For correct quantity, see chapter "Maintenance".

Filling valve alarm by 3 minutes time relay.

No pressure in the propelling liquid feed system.

Check operating of the propelling liquid pump. Check the suction line for air leakage and clogging.

Piping system from outlet valve to the propelling liquid tank is clogged or damaged.

Clean or replace. Outlet valve alarm by 3 minutes time relay.

Non-return valve in pipe between the outlet valve and the propelling liquid tank is clogged or damaged.

Clean or replace.

Much air is left in the propelling liquid chamber after maintenance work.

De-aerating the propelling liquid chamber.

The outlet valve does not open while there is an electric signal.

Check the diaphragm stroke control system.

Outlet valve alarm by 3 minutes time relay

Diaphragm is leaking and acts as a non-return valve.

Change the diaphragm and clean the total propelling liquid system.

Troubleshooting

201150-IOM-EN-R03 9.5

SLURRY SECTION: (abnormal noise and/or vibration) GENERAL: If the noise coming from the fluid end, then an attempt should be made to localize the source with the aid of a wrench or a stethoscope. If the noise can be localized, then it probably is of a mechanical source. If the noise seems general and difficult to locate, then the source might be a fluid knock. Problem/symptom Possible cause Remedy

Partially blocking of suction valve(s).

Check the permitted lifting of suction valve.

(Partially) blocked suction line. Check the clogged or not completely opened valves in the suction line.

Not completely filled propelling liquid chamber.

Filling valves in operation (see lamps on control panel).

Air in propelling liquid chamber(s).

De-aerating the propelling liquid chambers.

During the discharge stroke excessive vibrations or knocking due to not complete filling of one or more pump chambers during the suction stroke. Mostly also knocking in the discharge valves.

Air in slurry chamber De-aerating the slurry chamber. Suction feed pressure too low. Increase the suction pressure. Slurry temperature too high. Cooling of the slurry. Pulsation dampener not correctly pre-charged.

Pre-charge according to chapter "Maintenance".

Hammering noise near of just behind mid-stroke. Fluid hammer due to fluid separation (void) following collapsing in the pump chamber. This collapsing causes a hammering noise in the suction valves and a surge pressure well in the suction line. Diagnose by reducing pump speed.

Air level in Air vessel too low. Manually add a small amount of air until the hammering noise is disappeared.

Valve seal ring worn / valve seat worn (resulting in mechanical noise).

Replace the seal ring / valve seat.

Loose piston/cylinder liner. Tighten the connection. For the correct torque, see chapter "Maintenance".

Hammering noise in the piston dead points.

Suction or discharge valve, valve guide or valve spring worn.

Check and replace.

Slurry leaking under high velocity between the valve(s) and seat will cause wash out damage to valve(s) and seat or valve housing.

Check the valves and seats and replace if necessary.

If noise is heard during discharge stroke, then the problem is induced in the suction valve, if heard during suction stroke, then the problem is induced in discharge valve.

Check the valves and seats and replace if necessary.

Jetting noise in suction or discharge valve(s). Depending on the severity of the problem, a decreasing discharge flow may be observed.

No closing of suction or discharge valves.

Check and close the valves.

Troubleshooting

9.6 201150-IOM-EN-R03

Problem/symptom Possible cause Remedy

Surge pressure well, cause by fluid separation (void) and following collapsing in the pump chamber.

Reduce the pump speed.

Suction pressure too low.

Increase the suction pressure.

Propelling liquid chamber not completely filled.

De-aerate the propelling liquid chambers.

Hammering noise in the suction line, once per crankshaft revolution.

Surge pressure well in suction line, caused by malfunctioning of one suction valve.

Check the suction valve.

AIR SUPPLY UNIT: Problem/symptom Possible cause Remedy

Compression failure.

Check the air supply.

Air line is leaking.

Tighten the connections.

Air pressure is low.

Reducing valve on the air-conditioning device closed.

Open the reducing valve.


Troubleshooting

201150-IOM-EN-R03 9.7

Pos: 40 /GEHO/Troubleshooting/## Diaphragm pulsation dampener @ 0\mod_1156318158348_31.doc @ 5783 @ 25

9.2 Trouble shooting at a diaphragm pulsation dampener

Problem/symptom Possible causes and solutions

Safety

DANGER: Avoid breathing in nitrogen.

Make sure that the pulsation dampener is depressurized before loosening the pulsation dampener cover. Always loosen the cover nuts controlled.

General The pre-charge pressure at the diaphragm pulsation dampener shall be checked and noted at regular intervals.

• Keep a log book for settings and changes of the pre-charge pressure, so you can compare and observe changes.

The pre-charge pressure will normally be registered at the pressure gauge.

ATTENTION

If there is no liquid pressure at the pulsation dampener bottom, then the pressure gauge indicates only the pre-charge pressure.

If the liquid pressure at the pulsation dampener bottom is higher then the pre-charge pressure, then the pressure gauge indicates also the working pressure at the liquid site of diaphragm.

Under certain conditions the pressure gauge or filling line can be damaged or clogged with slurry and may then not indicate the right pressure. It is therefore important to recognize symptoms associated with a pre-charge pressure that is too low or too high. Such symptoms are excessive pressure fluctuations in piping or shock and vibrations in pump and piping.

Pre-charge pressure to high. 1 Check for causes.

Pre-charge pressure to low.


Determine the reason for any loss of gas and remedy the condition.

1 Do a leakage test.

Refer below to the section “Diaphragm outside leakage test”.

2 Check for other causes.

Pre-charge pressure loss. Determine the reason for any loss of gas and remedy the condition.

1 Do a leakage test.

Refer below to the section “Diaphragm outside leakage test”.

2 Increase the pre-charge pressure.

Refer to chapter “Pre-charging the diaphragm pulsation dampener”.

Troubleshooting

9.8 201150-IOM-EN-R03

Problem/symptom Possible causes and solutions

Measuring at the pressure gauge (manometer) excessive pressure fluctuations in the suction line or discharge line, or heavy vibrations.

1 The pressure gauge (manometer) is damaged. Replace the pressure gauge.

2 Pre-charge pressure to low. Check the pre-charge pressure.

Refer to chapter “Pre-charging the diaphragm pulsation dampener”.

Filling valve leakage.


1 Tighten loose threads.

2 Do a outside leakage test.

If there is still a leakage, then:

3 Release the nitrogen pressure carefully by opening slowly the filling valve.

4 Replace seal ring.

5 Replace filling valve.

Pressure gauge leakage at the gauge cover or at the lock cover.

1 Replace the pressure gauge.

Pressure gauge leakage at the thread or at the nipples.

1 Tighten loose threads.

2 Replace threaded nipples.

3 Replace pressure gauge.

Diaphragm leakage.


Fluid can have clogged the filling valve or the pressure gauge.

1 Release the nitrogen pressure carefully by opening slowly the filling valve.

2 Replace the diaphragm.

Refer to “Replacing the pulsation dampener diaphragm”.

Diaphragm pulsation dampener outside leakage test

DANGER

Avoid breathing in nitrogen.

1 Apply a leak detector to the pulsation dampener. Use soapy water.

2 Watch for bubbles.

3 Use the table above to solve the problem.

If the outside leakage test fails and the pressure still drops, then a diaphragm leakage is probably. Pos: 41 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @

Troubleshooting

201150-IOM-EN-R03 9.9

Pos: 42 /GEHO/Troubleshooting/## Typical wear (T)ZPM @ 1\mod_1169136581763_31.doc @ 11849 @ 2355535555355355553555

9.3 Typical wear phenomena and its causes

9.3.1 Valves

Figure 9.1

Normal wear

The valve seal ring looses material at side (1), and after a longer running period the overhanging material (A) is worn away. The length of this running period depends on the slurry abrasivity and particle size and has to be determined by experience. After this running period the seal ring must be turned in order to use side (2) (in case of using a cone valve) or replaced (in case of using a ball or mushroom valve) because there is no elastic sealing any more. Installing a suction strainer will increase the wearing life of the valve parts.

Local severe wash-out

Possible causes:

• Too long running period with worn valves and/or seats.

• Valves do not really close because of too large solid particles or a foreign object.

• Worn upper valve guide in which the clearance in one direction is excessive.

• Sticking upper or lower guide.

• Broken valve spring.

Wash outs at the outside diameter of the valve, valve seat and valve disc

Possible causes:

• Wash outs at the valve seat outside.

• Improper seat installation in the valve housing, or rust at the valve seat, or dirty or greasy surfaces.

• Damaged surfaces from valve seat or valve housing bore.

• Damaged from O-rings.

• Wrong O-ring assembly.

Troubleshooting

9.10 201150-IOM-EN-R03

9.3.2 Pump diaphragm

Normal wear by fatigue:

If the diaphragm is broken by fatigue, then it shows near the clamping edge a crack and mostly more surfaces cracks, especially at the propelling liquid side.

Blown up diaphragm

A blown up diaphragm by too much propelling liquid shows at the top section of the diaphragm a crack and some scratches due to deformation of the diaphragm in the discharge valve opening.

Teared-off in-vulcanized cone-plate in diaphragm

The cause might be fluid hammer in the slurry section for extended period or seizing of monitoring rod.

Damage at the propelling liquid side of the diaphragm

If rubber has loosened at the in-vulcanized cone-plate area, then the pump was probably running with insufficient propelling liquid and the vulcanized valve has touched the rear wall.

Possible causes:

• Pump discharge valve leaking, keeping propelling liquid chamber under discharge pressure during suction stroke.

9.3.3 Pulsation dampener diaphragm

Normal wear by fatigue

If the diaphragm is broken by fatigue, then it shows a crack near the biggest diameter, and perhaps more local surface cracks.

Damage of the in-vulcanized valve

Rubber from the diaphragm surface, near the vulcanized valve, lost by striking against the pulsation dampener inlet.

Possible causes:

• Pre-charge pressure of the pulsation dampener was too high.

Troubleshooting

201150-IOM-EN-R03 9.11

9.3.4 Piston

Normal wear

Normal worn piston seal rings show an equal wear around the outer diameter, so there is no pre-sealing effect any more.

Seal rings granulated surface

The rubber was burned by insufficient lubrication and cooling.

Possible causes:

• Piston flushing system works insufficiently.

• Running of the piston in a dry cylinder liner.

Grooves over the piston seal rings

Possible causes:

• Piston was running in a worn grooved cylinder liner.

• Propelling liquid chamber was not clean.

• Flushing oil is contaminated.

• Diaphragm rupture.

Severe wear at a part of the circumference

Possible causes:

• The piston guide ring is worn (mostly lower side).

• Alignment of the piston rod - crosshead rod was incorrect:

• Damaged contact surface.

• Dirty contact surface.

• Piston flushing pipe partly clogged, which causes insufficient lubrication of the piston seal rings at one side.

9.3.5 Cylinder liner

Normal wear

A normal worn liner shows a light grooved surface. The inner diameter is increased, mostly in the center of the piston stroke where the piston velocity is highest. The wear is raising rapidly when the hard layer in the cylinder liner is worn away.

Grooved cylinder liner after a relatively short operation time.

Possible causes:

• Propelling liquid chamber is insufficiently flushed and cleaned after diaphragm rupture.

• Propelling liquid in the tank is contaminated and flushing oil is dirty.

• Piston guide ring worn, by which the piston body rubs against the cylinder liner.

Severe wear at a part of the circumference

Possible causes:

• The piston guide ring was worn (mostly the lower side). Pos: 43 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Assembly and disassembly

201150-IOM-EN-R03 10.1

Pos: 44.1 /GEHO/Heading/H1/#. Assembly and disassembly @ 0\mod_1136455386113_31.doc @ 935 @

10 Assembly and disassembly Pos: 44.2 /GEHO/Assembly and Disassembly_during lock-out/General/## Introduction - Safety notes (T)ZPM @ 0\mod_1145882820736_31.doc @ 3352 @ 2555

10.1 Safety instructions

ATTENTION

• Do not hesitate to contact the Service Department of Weir Minerals Netherlands b.v., if problems occur during maintenance or repair activities.

INFORMATION

Refer to the drawings in chapter "Parts - Lists and drawings" (pump section) for correct positions of the ID numbers, mentioned in the text and not visible figures.

Refer to chapter "Parts - Lists and drawings (special tools)" for the use of special tools.

DANGER

• Strictly obey to all instructions as given in the chapter "Safety" of this manual.

The correct working sequence along with the data in this manual is of the utmost importance for safe operation and handling.

• Only authorized and properly trained people are allowed to work with the pumps.

• Only use original and undamaged GEHO parts.

DANGER

For safe working on the pump, it is mandatory, that the installation is locked out from all energy sources:

Pump lock-out procedure

• Stop the pump, refer to chapter "Operation".

• Lock-out the power supply to the main motor, lock the main switch.

• Lock-out the power supply to the lubrication oil motor.

• Lock-out the power supply to the propelling liquid motor.

• Lock-out the power supply to the control panel.

• Lock-out the power supply of all other applicable components.

• Stop and dis-connect the air supply only, when working on the air-actuated valves.

Refer to chapter "Operation", "STOP for maintenance procedure".

DANGER

For safe work on the pump parts, this is mandatory:

Slurry section isolation and drain procedure

1 Close and secure the pump isolation valves in the discharge line. 2 Close and secure the pump isolation valves in the suction line. 3 Flush clean the pump slurry section.

Refer to chapter "Operation", "STOP for maintenance procedure".

DANGER

For safe work on the pump parts at the propelling liquid section, this is mandatory:

1 Drain the propelling liquid at the diaphragm.

Refer to chapter "Assembly and disassembly", "Propelling liquid drain".


10.2 201150-IOM-EN-R03

DANGER

Hydraulic tool pressurizing procedure

If tools are operated hydraulically, then:

• Use only suitable tools and parts for this work.

• Before pressurizing a hydraulic tool: Check the hydraulic pump, all the hoses, nipples and tools, and de-aerate all the parts and tools.

• During pressurizing and 1 minute after reaching pressure level, no person is allowed to be in front of the tool. Always stay aside.

• Watch the pressure gauge. If the pressure does not build-up steady, then the stud bolts are not stretching equally. If the pistons come out further (without adding oil), then this indicates that the stud bolts are failing.

If this happens, then:

• Relief the oil pressure, replace these stud bolts by new ones and restart the procedure.

Pos: 44.3 /GEHO/Transport and installation/Transport and lifting/### lifting eyes @ 5\mod_1221653262294_31.doc @ 38469 @ 3

10.1.1 Lifting eye bolts

WARNING

The heavy parts of the pumps are provided with one or more lifting eye bolts, or have the possibility to install a lifting eye for transportation purposes. • Always transport these parts by using these eyes.

Table according to DIN 580 "LIFTING EYE BOLTS": Working Load Limit (= WLL) [kg]

Size (metric thread)

M8 M10 M12 M16 M20 M24 M27 M30 M33 M36 M42 M56 M64

only for 1 eye bolt, hoisting upwards

140 230 340 700 1200 1800 2500 3600 4300 5100 7000 11500 16000

for 2 or more eye bolts together

95 170 240 500 830 1270 1800 2600 3100 3700 5000 8300 11000

• If 2 or more lifting eye bolts are used, then the minimum hoisting angle is 45 degrees, as shown in the figure.



201150-IOM-EN-R03 10.3

Pos: 44.5 /GEHO/Heading/H2/#.# Manual rotation of the pump crankschaft @ 0\mod_1145881352537_31.doc @ 3343 @

10.2 Manual rotation of the pump crankshaft Pos: 44.6 /GEHO/Assembly and Disassembly_during lock-out/General/Manual rotation/###(T)ZPM-gearbox-R00=MANUAL CRANK UNIT via gearbox socket wrench-no blockade tool @ 11\mod_1296478189234_31.doc @ 80692 @ 35555

10.2.1 Manual rotation of the pump shaft with a socket wrench at the gearbox.

Manual rotation the pump shaft is required for: • For "priming" of the pump during the start-up procedure. • For turning a piston in a necessary position during inspection or maintenance. • For assembling or dis-assembling of several components within the pump.

DANGER

Be aware that the un-balance of the crankshaft-assembly causes un-stable positions. This un-balance causes a torque at the crankshaft, that will vary during rotation and can trigger unexpected sudden rotation of the crankshaft. There is a risk of a "run-away" of the pump crankshaft, turning forwards or backwards, causing movement of the connected parts in the pump frame (like crossheads and rods and pistons) and turning parts in the drive train (like couplings, gearbox and motor).

Preparation for rotation during the "priming" procedure

Refer to the chapter "Start-up, priming procedure".

Preparation for rotation during work on the pump

1 Switch-off the power from the main motor and lock the switch.

DANGER

• Make sure that the main motor can not be operated during the maintenance work.

2 Open the drain valve of the discharge line and the suction line, to release the pressure from the slurry section. Be aware that some static slurry pressure can remain at the diaphragm and the pistons, due to open or leaking discharge valves or suction valves.

3 Opening the drain valves of every propelling liquid section, to release the oil pressure from the pistons and the related forces from the crankshaft.

Procedure rotation at the gearbox

1 Remove the safety guard from the non-driven end of the high speed primer gearbox shaft. This will actuate the electric switch and will inhibit the start of the electric main motor.

2 Start the lubrication pump, to assure lubrication during turning of the pump shaft. Check that the lubrication system delivers the oil pressure and oil quantity.

3 Use the special tool "MANUAL CRANK UNIT".

Refer to chapter "Parts - List and drawings (special tools)" for details of this tool.

A Socket wrench B Socket, fitting on the hexagon of the shaft C Hexagon at the primer shaft of the gearbox

(normally hidden under the safety guard)

The figure shows a schematic arrangement for more versions. Depending on the supplier of the gearbox and its construction, the details can be different.

ABC

Figure 10.1: Special tool "MANUAL CRANK UNIT"

4 Put the socket (B) on the socket wrench (A).

DANGER

• Fore safety reasons, NEVER do this work alone. • The rotation tool shall always be operated with a tight grip and shall be locked firm,

to prevent uncontrolled crankshaft movement. • To avoid the risk of a crankshaft run-away, never use a tool in the ratchet position.


10.4 201150-IOM-EN-R03

5 Put the "MANUAL CRANK UNIT" on the hexagon shaft extension (C) of the gearbox. 6 Manually rotate the pump crankshaft with the socket wrench (A) the pump crankshaft into the required

position. Preferable, turn with the socket wrench the crankshaft in its stable balance position.

Refer for details to the related chapter.

7 If applicable, then use a rotation-blockade for the gearbox and the crankshaft. 8 Remove the "MANUAL CRANK UNIT".

Finishing the procedure

1 If applicable, then remove the rotation-blockade. Be aware, that the crankshaft can start to rotate to a rest position.

2 Mount the safety guard at the non-driven end of the high speed gearbox shaft. 3 Depending on the further working process, if no rotation of the pump crankshaft is needed,

then stop the lubrication pump. Pos: 44.7 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.5

Pos: 44.8 /GEHO/Assembly and Disassembly_during lock-out/General/Manual rotation/### TZPM crankshaft balance @ 8\mod_1258633343546_31.doc @ 56833 @ 35

10.2.2 Balance position of the TZPM crank shaft

DANGER

Be aware that the un-balance of the crankshaft-assembly causes un-stable positions. This un-balance causes a torque on the crankshaft, that will vary during rotation and can trigger unexpected sudden rotation of the crankshaft. There is a possibility of a "run-away" of the pump crankshaft, turning forwards or backwards, causing movement of the connected parts in the pump frame (like crossheads and rods and pistons) and turning parts in the drive train (like couplings, gearbox and motor).

• Only work on the crankshaft, the couplings and the pistons, if the un-balanced dead weight of the crankshaft is in its lowest position, or if the crankshaft is blocked safely against rotation.

• For safety reasons, NEVER do this work alone.

DANGER

Always first make sure, that there are no additional forces from the pistons or from the drive train, before turning a crankshaft in its balance position. 1 Switch of the power from the main motor and lock the switch. 2 Drain the slurry section. Refer to the related chapter. 3 Drain the propelling liquid section. Refer to the related chapter.

A

B

C

D

E

Figure 10.2: TZPM balance position of the crankshaft (if there are no additional forces from the pistons or from the drive train)

A Crankshaft of the TZPM pump, the viewpoint is from the driven shaft side B Gravity centre of the crankshaft C Threaded hole points downwards, indicating the gravity centre of the crankshaft

(the holes are made for handling the crankshaft during assembly) D+E Threaded holes

Procedure

1 Remove the cover of the crankshaft compartment of the frame. 2 Find the threaded hole (C) at the crankshaft in the ring. Refer to the figure above for the viewpoint. 3 Turn the crankshaft, until the threaded hole (C) points downwards, as shown in the figure above.

DANGER

Only if the threaded hole (C) points downwards (as shown above), then the gravity center of the crankshaft is under the center line of the crankshaft, in a stable balance position (if there are no additional forces from the pistons or the drive train). This position is required for working: • on the coupling between the gearbox and the pump, • on internal parts of the pump frame, like crankshaft, crossheads, rods and pistons. In any other position, the crankshaft is NOT in balance, and can start turning by itself.



10.6 201150-IOM-EN-R03

Pos: 44.10 /GEHO/Heading/H2/#.# Special tools @ 1\mod_1166540615553_31.doc @ 11465 @ 2

10.3 Special tools Pos: 44.11 /GEHO/Assembly and Disassembly_during lock-out/General/Hydraulic pump unit/### Air driven hydraulic pump @ 0\mod_1156403099735_31.doc @ 5821 @ 344

10.3.1 Air driven hydraulic pump

Some tools are operated hydraulically. The air driven oil pump generates a hydraulic pressure, displayed at the pressure gauge. A high pressure hose is connected to the hydraulic pump. All hydraulic tools are fitted with quick release connectors (“nipples”).

10.3.1.1 Legend

A Hydraulic connector B High pressure hose C Operating handle D Air pressure supply connector E Hydraulic pressure gauge

10.3.1.2 Operating instructions

1 Connect the hydraulic connector (A) to the according quick release connector (“nipple”).

2 Pressurize the hydraulic pump. 3 Turn the operating handle (C) to pressurize

the tool to be operated. 4 Check the pressure gauge (E).

Refer to chapter “Technical data”, "Special torques" for the appropriate pressure.

A

B

D

E

C

Figure 10.3: Air driven hydraulic pump Pos: 44.12 /GEHO/Assembly and Disassembly_during lock-out/General/### Oil connector caps at (T)ZPM pump @ 4\mod_1214468883644_31.doc @ 36433 @ 3

10.3.2 Oil connector caps

CAUTION

• Avoid wasting oil. • Avoid polluting the oil and the connectors.

If dis-connecting oil tubes or hoses, then:

• Use connector caps, to close the connection and to avoid waste of oil.

Figure 10.4: Oil connector caps Pos: 44.13 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.7

Pos: 44.14.1 /GEHO/Heading/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452 @

10.4 Drive unit Pos: 44.14.2 /GEHO/Assembly and Disassembly_during lock-out/Drive unit/Disassembly and assembly @ 1\mod_1168951193156_31.doc @ 11775 @

ATTENTION

Refer to chapter "Catalogue information" for information about assembly and disassembly of drive unit parts.

Pos: 44.15.1 /GEHO/Heading/H2/#.# Frame unit @ 0\mod_1146735364754_31.doc @ 3598 @

10.5 Frame unit Pos: 44.15.2 /GEHO/General/Attention, Warning and Note/Information - Frame unit - Contact Weir Minerals @ 1\mod_1165496458248_31.doc @ 9075 @

INFORMATION

• For major maintenance work on the frame unit, please contact the service department of Weir Minerals Netherlands b.v.



10.8 201150-IOM-EN-R03

Pos: 44.17 /GEHO/Heading/H2/#.# Lubrication system @ 0\mod_1152094184716_31.doc @ 5126 @

10.6 Lubrication system Pos: 44.18 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/### Environment instructions @ 8\mod_1255956478091_31.doc @ 55821 @ 3

10.6.1 Environment instructions

ATTENTION

• Make sure that the storage and/or disposal of the oil is according to the local environmental regulations.

• Before re-using the oil, check the oil quality for contamination and chemical properties. Options: • External full oil diagnosis by an authorized laboratory. • Internal oil diagnosis with an on-site analysis equipment.

Like a "Shell LubeClinic On-site analysis" set. • Internal optical diagnosis of the oil.

Look for changes of the oil and contaminations in the oil, caused by a leaking diaphragm. Like the oil color, solids from the slurry, fluid from the slurry, or water from the flushing water.

Pos: 44.19 /GEHO/Heading/H5/H5 Discharge filter @ 8\mod_1260358440906_31.doc @ 57715 @ 5

Discharge filter Pos: 44.20 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Lubrication system/Change the discharge oil filter/### Replace single oil filter+bypass @ 0\mod_1152779323482_31.doc @ 5251 @ 3 ┐┐┐

10.6.2 Change the oil filter

DANGER

• Do this procedure only during shut-down and lock-out of the pump.

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists + instruments", and to chapter "Catalogue information" for the specification of the oil filer and for details and specifications of the filter housing.

1 Set the lever to position:

2 Remove the filter cover.

3 Remove the old filter.

4 Clean the filter cover and housing.

5 Install the new filter.

6 Check the O-ring. If necessary, then replace the O-ring.

7 Install the filter cover.

8 Set the lever to position:

Figure 10.5: Single oil filter with bypass



201150-IOM-EN-R03 10.9

Pos: 44.22 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Lubrication system/### Replace the pump lubrication oil+suction filter @ 0\mod_1152098136341_31.doc @ 5155 @ 34444

10.6.3 Replace the pump lubrication oil and the oil suction filter inside the frame

10.6.3.1 Remove the oil

1 Open the frame unit cover. 2 Drain the oil through the oil drain valve, ore use a pump. 3 Remove the remaining oil from the oil sump.

10.6.3.2 If applicable, clean and/or replace parts inside the pump frame

1 Loosen the oil filter cover. 2 Remove the oil filter cover. 3 Remove the oil filter from the oil filter housing. 4 Clean:

• the oil filter cover.

• the oil filter housing.

• the oil sump.

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists + instruments" and also to chapter "Catalogue information" for the specification of the oil filer and for details and specifications of the filter housing.

5 If a "SUCTION STRAINER" is installed (instead of a filter), then clean this part. 6 If an oil filter is installed, then mount a new suction oil filter into the oil filter housing. 7 Check the O-ring.

If necessary, then exchange the O-ring. 8 Install the oil filter cover. 9 Tighten the oil filter cover.

10.6.3.3 Replace all oil filters in the oil suction line and oil discharge line

• If necessary, then exchange the filters.

Refer to the concerning chapters in this manual.

10.6.3.4 Fill the oil in the pump frame

Refer to chapter "Start and stop procedure", "Initial lubrication filling" for the procedure.

1 Fill in the new oil. Use a pump. 2 After replacing the oil, check the liquid level at the level gauge. 3 After starting-up the pump, check again the oil level at the level gauge. 4 If necessary, then add or drain oil. Pos: 44.23 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Frame unit-maintenance oil/### Replace the venting filter-top-nofig @ 2\mod_1174995485185_31.doc @ 12836 @

10.6.4 Replace the venting filter at the pump power end

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists + instruments" and also to chapter "Catalogue information" for details and specifications of the air filter.

1 Open the air filter cover. 2 Remove the filter element from the air filter housing. 3 Insert the new filter element into the air filter housing. 4 Close the air filter cover.



10.10 201150-IOM-EN-R03

Pos: 44.25.1 /GEHO/Heading/H2/#.# Propelling liquid drain @ 7\mod_1255089725997_31.doc @ 55208 @

10.7 Propelling liquid drain Pos: 44.25.2 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/### Environment instructions @ 8\mod_1255956478091_31.doc @ 55821 @ 3


ATTENTION





Pos: 44.25.3 /GEHO/Heading/H3/#.#.# Propelling liquid drain preparation @ 7\mod_1255090251455_31.doc @ 55238 @

10.7.2 Propelling liquid drain preparation Pos: 44.25.4 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/Propelling liquid drain preparation @ 7\mod_1255089532001_31.doc @ 55179 @ 5

Clean the slurry section

1 Do the ""STOP" procedure for flushing", to avoid dried slurry in the slurry section.

Refer to that procedure in chapter "Operation". Pos: 44.25.5 /GEHO/Heading/H3/#.#.# Propelling liquid drain procedure @ 7\mod_1255090131941_31.doc @ 55219 @

10.7.3 Propelling liquid drain procedure Pos: 44.25.6 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/DANGER only during shut-down main pump motor @ 7\mod_1255090729382_31.doc @ 55247 @ 5

DANGER

• Do this procedure only during shut-down and lock-out of the main pump motor.

Lock and tag the power supply of this main motor of the pump. • Keep in operation (do not turn off):

• The "GEHO HMI TOUCH PANEL", to monitor the display functions. • The air supply, to operate the pneumatic assisted valves.

De-pressurize the propelling liquid system

DANGER

1 Make sure that the propelling liquid pump is shut down. Lock and tag the power supply of this oil pump.

• If applicable, the following procedure can be used for one single diaphragm or for all diaphragms together at the same time. Pos: 44.25.7 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.11

Pos: 44.25.8 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/(T)ZPM Propelling liquid drain procedure @ 7\mod_1255089590562_31.doc @ 55189 @ 454544

10.7.3.1 Drain the contaminated propelling liquid into a container

ATTENTION For the draining of the contaminated propelling liquid oil, this procedure drains as much as possible oil into the disposal container. Use this procedure, if the works are related to: • leakage of slurry though the diaphragm into the propelling liquid, • by collecting the oil for disposal, • and to avoid contamination in the oil tank.

1 Place a (suitable large enough clean) container under the drain plug(s) of the propelling liquid chamber(s).

2 Make sure, that there is no pressure in the propelling liquid chamber(s). If applicable, relief the pressure from the slurry side of the diaphragm.

3 Open the drain plug(s) of the propelling liquid chamber(s). The oil will drain into the container.

4 Apply a flush-water pressure of 200-300 kPa (2-3 bar / 29-44 psig) on the slurry side of the diaphragms.

5 The flush-water pressure pushes the diaphragms back into their rear position. The oil in the pump chamber will drain, through the drain hole(s), into the container.

6 Monitor at the "GEHO HMI TOUCH PANEL" the filling lights (= indicating the position of the diaphragm monitoring rod). When a filling light are lit, then the diaphragm is in its rear position.

7 Wait until no oil comes out of the drain holes. 8 Open the vent valve at the "PRESSURE LIMITATION UNIT", to de-pressurize this unit. 9 Place a (suitable large enough clean) container under the drain plug of the "PRESSURE LIMITATION

UNIT". 10 Open the drain plug of the "PRESSURE LIMITATION UNIT", to drain this unit.

CAUTION

The tubes between the vent valves at the diaphragm housing and the non-return valve can still contain some remaining oil pressure (50 kPa / 0.5 bar / 7.3 psig).

11 Open for a short period one vent valve at the diaphragm housing, to relief the pressure.

Flushing the oil piping

1 Open the propelling liquid "FILLING VALVE" (located at the hydraulic skid). Refer to the "P&I DIAGRAM" for the functions and location and tagging of these valves. These valves can be operated at the "GEHO HMI TOUCH PANEL" in a manual service mode. Pushing the button "PROPELLING LIQUID SUPPLY VALVE 15 MINUTES" opens for 15 minutes the line from the oil pump to the propelling liquid chambers. This action relieves the pressure from the oil side of the accumulator and drains the oil, through the "FILLING VALVE", the piping, the propelling liquid chamber and the drain holes, into the container.

2 Start for 1 minute the propelling liquid pump, to flush the piping to the propelling liquid chambers.

DANGER

• Stop the propelling liquid pump. Lock and tag the power supply of this oil pump.

3 Wait until no oil comes out of the drain holes.


10.12 201150-IOM-EN-R03

10.7.3.2 Drain the clean propelling liquid into the oil tank

ATTENTION

For re-use of the clean propelling liquid oil, this procedure drains as much as possible oil via the flushing compartment into the oil tank. Use this procedure only, if you can assume, that the propelling liquid is clean and not contaminated (like for regular inspections or maintenance works).

1 Remove cover above the flushing compartment, to watch the oil flow from several units, via this compartment to the oil tank.

2 Open the vent valve at the "PRESSURE LIMITATION UNIT" (to de-pressurize and drain this unit). The oil flows through the piping into the oil tank.

3 Open the 3/2 outlet / release valve(s) (near the accumulator) of the propelling liquid section, to de-pressurize the oil pump discharge side of the propelling liquid system. This also drains the oil side of the accumulator, through the piping, into the oil tank. The propelling liquid chambers remain filled.

4 Apply a flush-water pressure of 200-300 kPa (2-3 bar / 29-44 psig) on the slurry side of the diaphragms.

5 Open the propelling liquid "OUTLET VALVES" (located at the hydraulic skid). Refer to the "P&I DIAGRAM" for the functions and location and tagging of these valves. These valves can be operated at the "GEHO HMI TOUCH PANEL" in a manual service mode. Pushing the button "MANUAL OUT" opens the line from the propelling liquid chambers to the oil tank.

6 The flush-water pressure pushes the diaphragms back into their rear position. The oil in the pump chamber will drain, through the "OUTLET VALVES", into the oil tank.

7 Monitor at the "GEHO HMI TOUCH PANEL" the filling lights (= indicating the position of the diaphragm monitoring rod). When a filling light is lit, then the diaphragm is in its rear position.

8 Wait until no oil flows into the oil tank.

Drain the remaining clean propelling liquid into a container

9 Place a (suitable large enough clean) container under the drain plugs of the propelling liquid chambers. 10 Open the drain plug(s) of the propelling liquid chamber(s).

The oil will drain into the container. 11 Wait until no more oil comes out of the drain holes.

CAUTION

The tubes between the vent valves at the diaphragm housing and the non-return valve can still contain some remaining oil pressure (50 kPa / 0.5 bar / 7.3 psig).

12 Open for a short period one vent valve at the diaphragm housing, to relief the pressure.

10.7.3.3 Oil treatment

1 For a diagnosis of possible problems and causes, inspect the oil in the container for contaminations of solids (from slurry) or water (from a leaking diaphragm).

2 If the oil in the container is not contaminated, then you can filter and re-use the oil in the container. If the oil in the container is contaminated, then dispose it, according to the local environmental regulations.

10.7.3.4 Propelling liquid filling + start-up

Refer to chapter "Replace the propelling liquid + the suction filter" for details to re-fill the oil tank. Refer to chapter "Start-up, priming procedure" to fill the propelling liquid chambers. Pos: 44.26 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.13

Pos: 44.27 /GEHO/Heading/H2/#.# Propelling liquid system @ 0\mod_1152094190955_31.doc @ 5132 @

10.8 Propelling liquid system Pos: 44.28 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/### Environment instructions @ 8\mod_1255956478091_31.doc @ 55821 @ 3


ATTENTION





Pos: 44.29 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/Refer to chapter "Propelling liquid drain" @ 8\mod_1255524757737_31.doc @ 55549 @

Drain the propelling liquid.

Refer to chapter "Propelling liquid drain" for a safe and proper procedure. Pos: 44.30 /GEHO/Heading/H5/H5 Discharge filter @ 8\mod_1260358440906_31.doc @ 57715 @ 5

Discharge filter Pos: 44.31 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Propelling liquid system-maintenance oil/### (Dis)assemble the discharge filter-singel/no-valve of the propelling liquid system @ 5\mod_1232022870344_31.doc @ 45412 @ 3

10.8.2 (Dis)assemble the discharge filter of the propelling liquid system

DANGER


1 Put a barrel under the discharge filter. 2 Remove the filter cover. 3 Remove the old filter. 4 Clean the filter housing and cover. 5 Put a new filter inside. 6 Check the O-ring.

If necessary, then change the O-ring. 7 Assemble the filter cover.

Pos: 44.32 /GEHO/Heading/H5/H5 Suction filter @ 8\mod_1260358408562_31.doc @ 57705 @ 5

Suction filter Pos: 44.33 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Propelling liquid system-maintenance oil/(Dis)assemble instruction propelling liquide suction filter in tank @ 5\mod_1221134876001_31.doc @ 38422 @ 33

10.8.3 Disassemble the suction filter at the propelling liquid tank

1 Stop the pump. 2 Drain the propelling liquid.

Use the drain valve on the propelling liquid tank. 3 Loosen the cover of the propelling liquid tank. 4 Remove the propelling liquid suction filter.

ATTENTION

• Do not loosen the filter at the filter connecting port. • Always disassemble the filter by loosen the stud coupling in the piping. By doing this, the end cap and connecting port of the filter will not be damaged.

5 Clean the propelling liquid tank. 6 Check the seal ring on the propelling liquid tank.


10.14 201150-IOM-EN-R03

10.8.4 Assemble the suction filter at the propelling liquid tank

1 Clean the propelling liquid suction filter. 2 Install the propelling liquid suction filter.

ATTENTION

• Do not tighten the filter at the filter connecting port. • Always assemble the filter by tighten the stud coupling in the piping. By doing this, the end cap and connecting port of the filter will not be damaged.

3 Close the drain valve on the propelling liquid tank. 4 Install the propelling liquid tank cover. 5 Open the inspection cover on the top of pump. 6 Add propelling liquid oil in the propelling liquid chamber.

Refer to chapter "Operation" for proper filling.

Pos: 44.34 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Propelling liquid system-maintenance oil/### Replace the propelling liquid+filters @ 0\mod_1152098068238_31.doc @ 5152 @ 355

10.8.5 Replace the propelling liquid and the filters

Propelling liquid drain

Refer to chapter "Propelling liquid drain" for a save and proper procedure.

Replace the propelling liquid

1 Open the propelling liquid tank drain valve. 2 Open the propelling liquid tank cover. 3 Clean the propelling liquid tank. 4 If applicable, replace the propelling liquid filter in the oil tank.

If applicable, replace the propelling liquid filter in the suction line. If applicable, replace the propelling liquid filter in the discharge line.

Refer to document "INSTRUMENT AND EQUIPMENT LIST" in chapter “Technical data”, for details.

5 Fill in the new propelling liquid.

Refer to document "UTILITY CONSUMPTION LIST" in chapter “Technical data”, for the correct oil type, quality and quantity.

6 After replacing the liquid, check the liquid level at the level gauge. 7 Close the propelling liquid tank cover. 8 After starting-up the pump, check again the liquid level at the level gauge. 9 If necessary, then add or drain liquid. Pos: 44.35 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Propelling liquid system-maintenance oil/### Replace proliq venting filter @ 0\mod_1152098314051_31.doc @ 5168 @ 3

10.8.6 Replace the venting filter at the propelling liquid system

DANGER


Refer to the document "INSTRUMENT AND EQUIPMENT LIST" in chapter "Technical data", "Drawings + lists + instruments" and also to chapter "Catalogue information" for details and specifications of the air filter.

1 Open the air filter cover. 2 Remove the filter element from the air filter housing. 3 Insert the new filter element into the air filter housing. 4 Close the air filter cover.



201150-IOM-EN-R03 10.15

Pos: 44.37 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/Propelling liquid system-maintenance oil/### 2/2 way valves: inspection and preservation @ 6\mod_1234348023224_31.doc @ 47301 @ 3

10.8.7 2/2 way valves: inspection and preservation

1 Dis-connect the air supply. 2 De-pressurize the propelling liquid piping,

by opening the 3-way valve at the accumulator. Refer for the location to the drawing "P&I DIAGRAM".

3 Remove the filter (002). 4 Inspect the filter (002).

If the filter (002) is clogged, then clean it with a duster blow gun blaster.

5 Assemble the filter (002). 6 Remove the valve covers (003) and the

valve internals. 7 Clean the air chambers up and below the

diaphragm (005).

007003004005

009002

001014011013012

008 Figure 10.6: 2/2 way valves inspection and conservation

8 Coat the air chambers below the diaphragm (005) with a suitable anti-corrosion agent. We recommend "Cortec VCI-369D". If the covers (003) are not coated, then coat them the same way.

9 Inspect the internals, especially the wear parts: Slide bearings (001 + 011, Valve spindle (014) and U-ring (013). If required, then replace the worn parts.

10 Grease all internals with suitable bearing grease. 11 Fill the space between the two slide bearings (001 + 011) and Valve spindle (014) with suitable grease. 12 Assemble the valves. 13 Before the next start of the pump, a de-aeration of the propelling liquid system and a priming of the

pump is required. Refer to the according procedures. Pos: 44.38 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/#### Initiator coupling nuts at the diaphragm housings @ 5\mod_1220445788139_31.doc @ 37905 @ 4

10.8.7.1 Initiator coupling nuts at the diaphragm housings

DANGER


The initiator coupling nuts at the diaphragm housings should not be tightened, to avoid heat expansion forces. 1 Screw every initiator coupling nut hand-

tight and then loosen about 45 degrees.

Figure 10.7: Initiator coupling nuts at the diaphragm housings




10.16 201150-IOM-EN-R03

Pos: 44.40 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Gearbox Hansen P4 @ 4\mod_1219650009052_31.doc @ 37642 @ 2344333

10.9 Gearbox maintenance

Refer to chapter "Maintenance" for the frequency of maintenance works. Refer to chapter "Catalogue Information", "Gearbox" for details about the gearbox maintenance, oil change and re-greasing. Refer to the "UTILITY CONSUMPTION LIST" for first oil filling, additional oil filling, greasing and re-greasing, or, if applicable, to the special instruction sticker at the gearbox.

10.9.1 Oil change

10.9.1.1 Oil draining

WARNING

• Drain the oil while the unit is still warm. • Be careful while draining the hot oil. • Use an appropriate recipient for the hot oil.

10.9.1.2 Oil filling

ATTENTION

Fill the gear unit exclusively through the oil filling opening, which is provided in the inspection cover. So all bearings are lubricated with fresh oil. After replacing the oil, check the liquid level at the level gauge.

10.9.2 Grease the bearings and labyrinth seals

The bearings and labyrinth seals need periodical greasing. • Check, how many grease nipples there are

at the gear box. • Add grease into the nipples.

Figure 10.8: Grease nipple at shaft ends


10.9.3 Cooling

If applicable, check regularly the fans, air-oil coolers, oil to water coolers or cooling coils. It is important that the generated heat in the gearbox due friction and churning of the oil can be dissipated.

10.9.4 Air filter

Clean or replace the air filter, at the top of the gearbox. Pos: 44.41 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.17

Pos: 44.42 /GEHO/Heading/H2/#.# Valves, angular model, in the discharge line @ 1\mod_1170947685604_31.doc @ 12232 @

10.10 Valves, angular model, in the discharge line Pos: 44.43 /GEHO/Technical data sheets/Special torques/Suction valve unit/H.831.020.378, drawing T.831.000.472 discharge @ 5\mod_1231253291524_31.doc @ 45032 @

Discharge "VALVE UNIT" = 831.020.378, drawing T.831.000.472 Pos: 44.44.1.1 /GEHO/Heading/H3/#.#.# Valve housing cover @ 0\mod_1147174241226_31.doc @ 3690 @

10.10.1 Valve housing cover Pos: 44.44.1.2 /GEHO/Heading/H4/#.#.#.# Disassembly @ 0\mod_1147174347836_31.doc @ 3696 @

10.10.1.1 Disassembly Pos: 44.44.1.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve housing cover/Hydraulic/Remove, High pressure block angular=nut "A" tight @ 1\mod_1162208470115_31.doc @ 6720 @ 5555

Preparation

DANGER

1 Flush and drain the slurry section. 2 Close and secure the isolation valves in the slurry suction line and discharge line,

to isolate the working area. 3 Drain the valve.

Refer to the chapter "Safety instructions".

K L M N O

X

Figure 10.9: Push-off bolts (start position before working) (The figure shows a schematic arrangement for more versions)

A B C D E F G HA B C D E F G H

Figure 10.10: Schematics of a hydraulically operated high pressure valve cover (The figure shows a schematic arrangement for more versions)

Tighten the housing nuts (A)

The housing nuts (A) maintain the tightening force in the stud (D), to keep the valve housing in position during the removal of the cover.

1 Tighten all the housing nuts (A) to the valve house side (L). Use the pin (H) with normal hand force.

Loosen the lock-nuts (E)

1 Remove the protection guard from the nipple (G) at the valve cover (K). 2 Connect the high pressure hose to the hydraulic connector nipple (G) and to the hydraulic high-

pressure pump. 3 Close the drain side of the oil-return/de-aerate valve at the hydraulic pump. 4 Pressurize with the hydraulic pump the pistons (B), to tension the stud bolts (D).

Refer to chapter "Technical data", “Special torques” for the correct pressure.

5 Loosen all the outside lock-nuts (E).

Refer to chapter "Technical data", “Special torques” for the applicable torques.


10.18 201150-IOM-EN-R03

6 Screw all the outside lock-nuts (E) against the hexagon surface of the inside strain-nuts (C) (= back to the start position).

7 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump, to de-pressurize the hydraulic system. Check this at the pressure gauge of the pump.

8 Disconnect the high pressure hose from the hydraulic connector nipple (G). Put the protecting guard to the connector nipple (G).

Remove the valve cover

1 Loosen all the inside strain-nuts (C). 2 Unscrew all the inside strain-nuts (C). 3 Lift the valve housing cover (K).

If necessary, then use the push-off bolts (M). 4 Remove the valve housing cover (K).

Use a lifting device. Use the provided lifting eye (O).

5 Remove the square gasket (N). Pos: 44.44.1.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.19

Pos: 44.44.1.5 /GEHO/Heading/H4/#.#.#.# Assembly @ 0\mod_1147174319423_31.doc @ 3693 @

10.10.1.2 Assembly Pos: 44.44.1.6 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve housing cover/Hydraulic/Install, High pressure block angular= nut "A" tight @ 1\mod_1162292450237_31.doc @ 6742 @ 555

Preparation

1 Clean and grease all the sealing surfaces and threat surfaces with suitable grease. 2 Tighten all the housing nuts (A) to the valve house (L).

Use the pin (H) with normal hand force.

ATTENTION

3 Make sure that all the push-off bolts (M) at the valve cover (K) stand back from the cover surface (to avoid contact with the top of the valve housing).

Refer to distance (X) in the figure below.

K L M N O

X

Figure 10.11: Push-off bolts, start position (The figure shows a schematic arrangement for more versions)

A B C D E F G HA B C D E F G H

Figure 10.12: Schematics of a hydraulically operated high pressure valve cover (The figure shows a schematic arrangement for more versions)

Place the valve cover

1 Insert a new square gasket (N) into the valve housing (K). 2 Fit the valve cover (K) to the valve housing (L).

Use a lifting device. Use the lifting eye (O). Make sure that the gasket (N) stays well in place.

3 Screw by hand all the locknuts (E) against the hexagon surface of the strain-nuts (C) (= start position).

4 Screw by hand all the strain-nuts (C) (including the lock-nut (E)) on the valve-studs (D) against the pistons (B).

5 Remove the protection guard from the connector nipple (G) at the valve cover (K). 6 Connect the high pressure hose to the connector nipple (G) and to the hydraulic high-pressure pump. 7 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump,

so during the next action, the oil can flow back from the pistons to the hydraulic pump sump. 8 Tighten all the strain-nuts (C) with the required torque.

This will push the pistons (B) into their start position against the cover, and the cover against the housing.

Refer to chapter “Technical data”, “Special torques” for the correct torque.

9 Pre-tighten all the outside lock-nuts (E) by hand to the cover, to secure the start position of the cover.


10.20 201150-IOM-EN-R03

Apply the stud tension

1 Close the oil-return/de-aerate valve at the hydraulic pump. 2 Pressurize the pistons (B) with the hydraulic pump, to tension the stud bolts (D).

Refer to chapter “Technical data”, “Special torques” for the correct pressures.

3 Re-tighten the lock-nuts (E). These lock-nuts (E) maintain the tightening force in stud (D) during operation of the pump.



5 Disconnect the high pressure hose from the connector nipple (G). Put the protecting guard to the connector nipple (G).

6 Tighten all the housing nuts (A) to the valve house (L). Use the pin (H) with normal hand force.



201150-IOM-EN-R03 10.21

Pos: 44.44.3.1 /GEHO/Heading/H3/#.#.# Conical valve @ 0\mod_1147176114890_31.doc @ 3735 @

10.10.2 Conical valve Pos: 44.44.3.2 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve/#### Remove, Angular, Standard @ 1\mod_1161247034668_31.doc @ 6533 @ 4

10.10.2.1 Disassembly

1 Release the pressure from the slurry section.

2 Remove the valve housing cover.

Refer to chapter "Remove the valve housing cover".

3 Remove the square gasket. 4 Remove the compression spring. 5 Remove the conical valve.

Figure 10.13: Remove the conical valve

(The figure shows a schematic arrangement for more housing versions)

Pos: 44.44.3.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve/#### Install, Angular @ 1\mod_1161247316353_31.doc @ 6535 @ 4

10.10.2.2 Assembly

1 Insert the conical valve. 2 Insert the compression spring 3 Install a new square gasket. 4 Install the valve housing cover.

Refer to chapter "Install the valve housing cover".

Figure 10.14: Insert the conical valve




10.22 201150-IOM-EN-R03

Pos: 44.44.5.1 /GEHO/Heading/H3/#.#.# Valve seat @ 0\mod_1147176079227_31.doc @ 3732 @

10.10.3 Valve seat Pos: 44.44.5.2 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Remove HySeat angular @ 0\mod_1147180524829_31.doc @ 3774 @


Remove the valve seat, using the hydraulic seat connector


Refer to chapter "Valve housing cover", "Disassembly".

2 Remove the conical valve.

Refer to chapter "Conical valve", "Disassembly".

WARNING

• Re-install the valve housing cover,

to prevent getting hit by a valve seat.

3 Install the valve housing cover.

Refer to chapter "Valve housing cover", "Assembly".

4 Remove the protection guard from the hydraulic connector. 5 Connect the hydraulic pump unit to the connector at the valve housing. 6 Pressurize the hydraulic pump unit until the valve seat is loose. 7 Release the pressure from the hydraulic pump unit. 8 Disconnect the hydraulic pump unit. 9 Remove the valve housing cover.


10 Remove the valve seat from the valve housing. Pos: 44.44.5.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Remove HyTool API 12+ (no rods) @ 5\mod_1227195327625_31.doc @ 44182 @

Remove the valve seat, using a hydraulic special tool set

Refer to chapter "special tools".


Refer to "Remove the valve cover".

2 Remove the valve and spring.

Refer to "Remove the valve".

3 Place puller (E) under the valve seat. 4 Screw the threaded spindle (C) into the

puller (E). 5 Put the centering plate (D) with the

hydraulic tool (B) to the valve housing. 6 Tighten the nut (A) until the hydraulic

tool (B) is compressed in its final position. 7 Connect the hydraulic pump to the

connector of the hydraulic tool (B). 8 Pressurize the pump until the valve seat is

loose. 9 Depressurize the pump. 10 Remove the pump. 11 Remove the valve seat.

A

B

D

E

C

Figure 10.15: Using the hydraulic valve seat tool.

(The figure shows a schematic arrangement for more tool versions.)

Pos: 44.44.5.4 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Install MechTool API 12- hamer tool @ 0\mod_1147179105600_31.doc @ 3769 @ 45


201150-IOM-EN-R03 10.23

10.10.3.2 Assembly

Install the valve seat, using a mechanical tool

1 Clean the valve seat. 2 Clean the bore in the valve housing. 3 Make sure that they are free of dust, paint,

or oil. 4 Insert new O-rings into the grooves at the

valve seat. 5 Insert valve seat (D) into the bore in the

valve housing. 6 Put valve seat tool (C) to the valve seat. 7 Tap valve seat tool (B+C) until the valve

seat (D) fits. Use a hammer (A).

8 Remove the valve seat tool. 9 Make sure that the valve seat is mounted

correctly and tight. If you can pull out the valve seat by hand, then inspect the surfaces of the housing and the valve, and repeat this procedure.

A

B

D

C

Figure 10.16: Using the mechanic valve seat tool

(The figure shows a schematic arrangement for more versions.)



10.24 201150-IOM-EN-R03

Pos: 44.46 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve disk/### Valve disk Disassembly and assembly @ 1\mod_1161260471084_31.doc @ 6573 @ 344

10.10.4 Valve disk assembly

10.10.4.1 Disassemble the valve disk

A Conical valve B Valve disc lock nut C Valve disc

1 Remove the valve disc lock nut (B). 2 Remove the valve disc (C) from the conical

valve (A).

A B C

Figure 10.17: The valve

10.10.4.2 Assemble the valve disk

1 Make sure that all valve parts are clean, dry and free of lubricant.

2 Put the valve disc (C) to the conical valve (A).

3 Apply a small amount of grease or soft soap to the surface (Y) of the valve disc lock nut (B).

ATTENTION

Do NOT use grease based on mineral oil.

4 Make sure that there is no grease on surface (X).

A B CYX

Figure 10.18: The valve

5 Put the valve nut wrench (A) to the assembled valve (B).

6 Tighten the valve disc lock nut.

Refer to chapter "Special torques" for the correct torque.

7 Make sure that the valve disc does not turn with the valve disc lock nut.

8 Make sure that valve disc lock nut and the valve disc are in full contact.

A B

Figure 10.19: Assemble the valve with the valve nut wrench.



201150-IOM-EN-R03 10.25

Pos: 44.48.1 /GEHO/Heading/H3/#.#.# Valve guide bush @ 1\mod_1165494162006_31.doc @ 9067 @

10.10.5 Valve guide bush Pos: 44.48.2 /GEHO/Heading/H4/#.#.#.# Overview @ 1\mod_1165494429019_31.doc @ 9072 @

10.10.5.1 Overview Pos: 44.48.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve guide bush/Standard/Overview, angular @ 1\mod_1165490064608_31.doc @ 9054 @

A Valve seat B Valve disc C Conical valve D Compression spring E Clamping piece locking screw F Guide groove for special tool G Clamping piece H Valve guide bush I Valve cover

DCA B E F GH I

Figure 10.20: Overview of a valve unit with hydraulic operated valve cover


Pos: 44.48.4 /GEHO/Heading/H4/#.#.#.# Disassembly @ 0\mod_1147174347836_31.doc @ 3696 @

10.10.5.2 Disassembly Pos: 44.48.5 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve guide bush/Standard/Remove angular-bush removal tool @ 1\mod_1165492029621_31.doc @ 9057 @

Use the procedure below, to remove the valve guide bush from the clamping piece. Check the guide bush: 1 Remove the valve housing cover. 2 Turn the valve housing cover until the

clamping piece (A) is visible. 3 Check the inner surface of the guide

bush (D). 4 If the guide bush (D) is worn-out or

damaged, then replace the guide bush (D). Replace the guide bush: 5 Remove the clamping piece locking screw. 6 Remove the clamping piece (A) from the

valve housing cover. 7 Put the clamping piece (B) into a vice. 8 Put the valve guide bush removal tool (B)

into the grooves (C) of the clamping piece (A).

9 Remove the valve guide bush (D) from the clamping piece (A). Use a hammer.

DCA B

Figure 10.21: The valve guide bush removal tool Pos: 44.48.6 /GEHO/Heading/H4/#.#.#.# Assembly @ 0\mod_1147174319423_31.doc @ 3693 @

10.10.5.3 Assembly Pos: 44.48.7 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve guide bush/Standard/Install angular @ 1\mod_1165492511437_31.doc @ 9060 @

1 Heat up the clamping piece to 220°C 2 Put the clamping piece into a vice or press. 3 Put the valve guide bush into the clamping piece. 4 Put the clamping piece to the valve cover. 5 Tighten the clamping piece locking screw.

Refer to chapter "Tightening torques" for the correct torque. Pos: 44.49 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


10.26 201150-IOM-EN-R03

Pos: 44.50 /GEHO/Heading/H2/#.# Valves, angular model, in the suction line @ 1\mod_1171463649895_31.doc @ 12436 @

10.11 Valves, angular model, in the suction line Pos: 44.51 /GEHO/Technical data sheets/Special torques/Suction valve unit/H.831.020.379, drawing T.831.000.441 suction @ 5\mod_1227107014546_31.doc @ 43993 @

Suction "VALVE UNIT" = 831.020.379, drawing T.831.000.441 Pos: 44.52.1.1 /GEHO/Heading/H3/#.#.# Valve housing cover @ 0\mod_1147174241226_31.doc @ 3690 @

10.11.1 Valve housing cover Pos: 44.52.1.2 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve housing cover/Hydraulic/Remove, Standard, Angelar @ 0\mod_1147163606938_31.doc @ 3669 @ 455


Preparation

DANGER

1 Flush and drain the slurry section. 2 Close and secure the isolation valves in the slurry suction line and discharge line, to

isolate the working area.

Refer to the chapter "Safety instructions". 3 Drain the valve. 4 Remove the protection guard from the

connecting nipple (E) at the valve housing cover (A).

5 Connect the high pressure hose to the connecting nipple (E) and to the hydraulic pump unit.

6 Pressurize the hydraulic pump unit.

Refer to chapter “Technical data”, “Special torques” for the correct pressure.

7 Loosen all the outside lock-nuts (D).


AB

C

D

E

F

G

H

Figure 10.22: Schematics of a hydraulic operated valve cover


8 Screw all the lock-nuts (D) against the hexagon surface of the inside strain-nuts (B). 9 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump,

to de-pressurize the hydraulic system. Check this at the pressure gauge of the pump.

10 Disconnect the high pressure hose from the hydraulic connector nipple (E). Put the protecting guard to the connector nipple (E).

Remove the valve cover

11 Loosen all the inside strain-nuts (B). 12 Unscrew all the inside strain-nuts (B). 13 Lift the valve housing cover (A).

If necessary, then use the push-off bolts (G). 14 Remove the valve housing cover (A).

Use a lifting device. Use the lifting eye (F).

Pos: 44.52.1.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve housing cover/Hydraulic/Install, Standard, Angular @ 0\mod_1147165917235_31.doc @ 3679 @ 4555


201150-IOM-EN-R03 10.27

10.11.1.2 Assembly

Preparation

1 Clean and grease all the sealing surfaces and threat surfaces with suitable grease.

2

ATTENTION

Make sure that all the push-off bolts (G) at the valve cover (A) are unscrewed and free from any contact with the top of the valve housing. Ensure a metal to metal fit between the valve housing cover and valve housing.

AB

C

D

E

F

G

H

Figure 10.23: Schematics of the hydraulic operated valve cover


Place the valve cover

3 Insert a new square gasket into the valve housing cover (A). 4 Fit the valve housing cover (A) to the valve housing (H).

Use a lifting device. Use the lifting eye (F). Make sure that the gasket stays well in place.

5 Screw by hand all the outside lock-nuts (D) against the hexagon surface of the strain-nuts (B). 6 Screw by hand all the inside strain-nuts (B) (including the lock-nut (D)) on the valve studs (C) against

the pistons.

Apply the stud tension

7 Remove the protection guard from the nipple (E) at the valve cover (A). 8 Connect the high pressure hose to the hydraulic connector nipple (E) and to the hydraulic high-

pressure pump. 9 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump,

so the oil can flow back from the pistons to the hydraulic pump sump. 10 Tighten all the inside strain-nuts (B).

This will push the pistons into their start position against the cover, and the cover against the housing.


11 Pre-tighten all the outside lock-nuts (D) by hand to the cover, to secure the start position of the cover. 12 Close the oil-return/de-aerate valve at the hydraulic pump. 13 Pressurize the pistons with the hydraulic pump, to tension the stud (C).

Refer to chapter “Technical data”, “Special torques” for the correct pressures.

14 Re-tighten the outside lock-nuts (D). These lock-nuts (E) maintain during operation the tightening force in stud (C).



16 Disconnect the high pressure hose from the hydraulic connector nipple (E). Put the protecting guard to the connector nipple (E).



10.28 201150-IOM-EN-R03

Pos: 44.52.3.1 /GEHO/Heading/H3/#.#.# Conical valve @ 0\mod_1147176114890_31.doc @ 3735 @

10.11.2 Conical valve Pos: 44.52.3.2 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve/#### Remove, Angular, Standard @ 1\mod_1161247034668_31.doc @ 6533 @ 4


1 Release the pressure from the slurry section.


Refer to chapter "Remove the valve housing cover".

3 Remove the square gasket. 4 Remove the compression spring. 5 Remove the conical valve.

Figure 10.24: Remove the conical valve

(The figure shows a schematic arrangement for more housing versions)

Pos: 44.52.3.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve/#### Install, Angular @ 1\mod_1161247316353_31.doc @ 6535 @ 4

10.11.2.2 Assembly

1 Insert the conical valve. 2 Insert the compression spring 3 Install a new square gasket. 4 Install the valve housing cover.

Refer to chapter "Install the valve housing cover".

Figure 10.25: Insert the conical valve




201150-IOM-EN-R03 10.29

Pos: 44.52.5.1 /GEHO/Heading/H3/#.#.# Valve seat @ 0\mod_1147176079227_31.doc @ 3732 @

10.11.3 Valve seat Pos: 44.52.5.2 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Remove HySeat angular @ 0\mod_1147180524829_31.doc @ 3774 @


Remove the valve seat, using the hydraulic seat connector



2 Remove the conical valve.

Refer to chapter "Conical valve", "Disassembly".

WARNING

• Re-install the valve housing cover,

to prevent getting hit by a valve seat.

3 Install the valve housing cover.

Refer to chapter "Valve housing cover", "Assembly".

4 Remove the protection guard from the hydraulic connector. 5 Connect the hydraulic pump unit to the connector at the valve housing. 6 Pressurize the hydraulic pump unit until the valve seat is loose. 7 Release the pressure from the hydraulic pump unit. 8 Disconnect the hydraulic pump unit. 9 Remove the valve housing cover.


10 Remove the valve seat from the valve housing. Pos: 44.52.5.3 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Remove HyTool API 12+ (no rods) @ 5\mod_1227195327625_31.doc @ 44182 @

Remove the valve seat, using a hydraulic special tool set

Refer to chapter "special tools".


Refer to "Remove the valve cover".

2 Remove the valve and spring.

Refer to "Remove the valve".

3 Place puller (E) under the valve seat. 4 Screw the threaded spindle (C) into the

puller (E). 5 Put the centering plate (D) with the

hydraulic tool (B) to the valve housing. 6 Tighten the nut (A) until the hydraulic

tool (B) is compressed in its final position. 7 Connect the hydraulic pump to the

connector of the hydraulic tool (B). 8 Pressurize the pump until the valve seat is

loose. 9 Depressurize the pump. 10 Remove the pump. 11 Remove the valve seat.

A

B

D

E

C

Figure 10.26: Using the hydraulic valve seat tool.

(The figure shows a schematic arrangement for more tool versions.)

Pos: 44.52.5.4 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve seat/Angular/Install MechTool API 12- hamer tool @ 0\mod_1147179105600_31.doc @ 3769 @ 45


10.30 201150-IOM-EN-R03

10.11.3.2 Assembly

Install the valve seat, using a mechanical tool

1 Clean the valve seat. 2 Clean the bore in the valve housing. 3 Make sure that they are free of dust, paint,

or oil. 4 Insert new O-rings into the grooves at the

valve seat. 5 Insert valve seat (D) into the bore in the

valve housing. 6 Put valve seat tool (C) to the valve seat. 7 Tap valve seat tool (B+C) until the valve

seat (D) fits. Use a hammer (A).

8 Remove the valve seat tool. 9 Make sure that the valve seat is mounted

correctly and tight. If you can pull out the valve seat by hand, then inspect the surfaces of the housing and the valve, and repeat this procedure.

A

B

D

C

Figure 10.27: Using the mechanic valve seat tool

(The figure shows a schematic arrangement for more versions.)

Pos: 44.53 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve disk/### Valve disk: Refer to previous @ 6\mod_1237214142416_31.doc @ 48562 @

10.11.4 Valve disk, disassembly and assembly

Refer to the related chapter of the previous valve. Pos: 44.54 /GEHO/Assembly and Disassembly_during lock-out/Valve unit/Conical valves/Valve guide bush/### Valve guide bush: Refer to previous @ 6\mod_1237213872552_31.doc @ 48551 @

10.11.5 Valve guide bush, disassembly and assembly

Refer to the related chapter of the previous valve. Pos: 44.55 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.31

Pos: 44.56 /GEHO/Technical data sheets/Special torques/Diaphragm housing unit/H.832.010.279, drawing T.832.000.250 @ 5\mod_1227107554999_31.doc @ 44015 @

"DIAPHRAGM HOUSING UNIT" - 832.010.279, drawing T.832.000.250 Pos: 44.57.1 /GEHO/Heading/H2/#.# Diaphragm housing unit @ 0\mod_1152094180650_31.doc @ 5123 @

10.12 Diaphragm housing unit Pos: 44.57.2 /GEHO/Heading/H3/#.#.# Disassembly @ 0\mod_1146735769451_31.doc @ 3613 @

10.12.1 Disassembly Pos: 44.57.3 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/@Overview#MMX+filling ring @ 5\mod_1231429364256_31.doc @ 45228 @

Overview

A Filling ring B Covering ring at the filling ring C Diaphragm housing D Screw at the filling ring (standard = 6x) E Diaphragm F Guide bush for the monitoring rod G Initiator housing H Screw for the guide bush

(standard = 2x, the position is 90°turned) I Screw at the covering ring (standard = 3x) R De-aeration holes

ABCDEFGHI

R

Figure 10.28: Pump diaphragm with filling ring


Pos: 44.57.4 /GEHO/Assembly and Disassembly_during lock-out/General/#### Flush and drain and de-pressurize the slurry section @ 5\mod_1232031630918_31.doc @ 45431 @

10.12.1.1 Flush and drain and de-pressurize the slurry section

1 Flush and drain the slurry section.

DANGER

2 Close and secure the isolation valves in the slurry suction line and discharge line, to isolate the working area.

Refer to the chapter "Safety instructions".

3 Drain the diaphragm housing. Pos: 44.57.5 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Common/#### Disassembly, Preparation de-pressurize+drain @ 1\mod_1164881888391_31.doc @ 8826 @

10.12.1.2 Preparation of the propelling liquid system

CAUTION

• De-pressurize the propelling liquid system, before starting works on the pump.

DANGER


1 De-pressurize the accumulator,

by opening the drain valve in the propelling liquid piping. 2 De-pressurize the propelling liquid chambers,

by opening the vent valves of the diaphragm housing units. 3 Open the drain plug of each propelling liquid chamber.

Collect the oil in a bucket. Pos: 44.57.6 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Loosen, single piston @ 0\mod_1156333407963_31.doc @ 5796 @ 455555


10.32 201150-IOM-EN-R03

10.12.1.3 Loosen the diaphragm housing cover

Preparation

1 Remove the protection cover from the diaphragm housing unit (D).

2 Remove eventually remaining push-bolds. 3 Use a special tool,

the "HYDRAULIC TENSION RING" (B). Refer to chapter "Special tools".

4 Place the "HYDRAULIC TENSION RING" (B) over the stud bolts. Use an appropriate lifting device. Use the lifting eye (A).

5 Hand-tighten all nuts (C) at the tension ring.

6 Disconnect the protection cap of the hydraulic quick release connector (E).

7 Connect the hose of the "HYDRAULIC PUMP UNIT" to the hydraulic quick release connector (E).

B

AF

D

C

E

Figure 10.29: Install the "HYDRAULIC TENSION RING".

De-aeration procedure (if necessary):

De-aeration is required, if the "HYDRAULIC TENSION RING" (B) is used the first time (= initial use), or if there is air in the hydraulic canals (so during hydraulic pressurizing the hydraulic system is compressible). 1 Remove the blind plug (F), to enable the de-aeration of the tool (B). 2 Close the drain side of the oil-return/de-aerate valve at the hydraulic pump. 3 Activate the "HYDRAULIC PUMP UNIT",

until hydraulic oil with no air bubbles leaks out of the hole (F). 4 Tighten the de-aeration hole with the blind plug (F).


201150-IOM-EN-R03 10.33

Legend

A Diaphragm housing cover B Hydraulic tension ring unit C Diaphragm housing cover stud bolt D Diaphragm housing cover nut E Pin (to turn the cover nut) F Tension-ring-nut

A B C D E F

Figure 10.30: "HYDRAULIC TENSION RING"

Preparation of the hydraulic pistons

ATTENTION

For a proper procedure, the pistons and tension ring nuts (F) and cover-nuts (D) the must be in their start position. All piston heads must be even with the top surface of the "HYDRAULIC TENSION RING" (B). As shown in the figure above.

1 Open the drain valve at the hydraulic pump,

to enable the pistons to move. 2 Screw all the tension-ring-nuts (F) into the position, that the nuts bottom surfaces are even with the

top surface of the "HYDRAULIC TENSION RING" (B). As shown in the figure above.

If some pistons heads where above the ring surface, then they have been pushed back into their start position with the tension-ring-nuts (F). If some pistons heads are below the ring surface, then they must be pushed back into their start position with the hydraulic pump. 3 Close the drain valve at the hydraulic pump. 4 Activate the "HYDRAULIC PUMP UNIT",

until the hydraulic oil pushed all those pistons against the tension-ring-nuts (F). 5 Check the positions of the piston heads.

Loosen the diaphragm cover nuts

1 Activate the "HYDRAULIC PUMP UNIT", to pressurize the pistons of the "HYDRAULIC TENSION RING".

Refer to chapter "Technical data", "Special torques", "Diaphragm housing unit" for the procedure and pressure.

2 Loosen all diaphragm housing cover nuts (D) with the pin (E). 3 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump,

to relief the hydraulic pressure at the tensioning ring. 4 Disconnect the hydraulic hose. 5 Put the protection cap on the connector. 6 Remove all tension-ring-nut (F). 7 Remove the "HYDRAULIC TENSION RING" (B).

Pos: 44.57.7 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Remove, Hoisting bracket @ 1\mod_1164889293953_31.doc @ 8839 @


10.34 201150-IOM-EN-R03

Remove the diaphragm housing cover

1 Use the special tool set "HOISTING TOOL DIAPHRAGM COVER".

2 Remove the two topmost cover nuts. 3 Remove the two lowest cover nuts. 4 Put the "HOISTING TOOL DIAPHRAGM

COVER" to the diaphragm cover. Make sure that the threaded bolts fit in the holes.

5 Tighten the "HOISTING TOOL DIAPHRAGM COVER" with two screws.

6 Remove the remaining cover nuts. 7 Remove the diaphragm housing cover.

Use the jack-off screws. 8 Remove the diaphragm housing cover seal

ring.

Figure 10.31: The "HOISTING TOOL DIAPHRAGM COVER"

Pos: 44.57.8 /GEHO/Heading/H4/#.#.#.# Diaphragm @ 1\mod_1165394045801_31.doc @ 9030 @ 4

10.12.1.4 Diaphragm Pos: 44.57.9 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm unit/Hydraulic/Remove @ 1\mod_1165319630222_31.doc @ 8947 @

1 Mark (clearly, with a permanent white marker) at the diaphragm (B) its top-side position (=12:00 o-clock) (to enable diagnosis after removing).

2 Remove the diaphragm (B) from the diaphragm housing (A).

3 Loosen and remove the monitoring rod (C) from the diaphragm (B).

4 Check the monitoring rod (C) for abnormal wear or damage.

5 If necessary, then replace the monitoring rod (C).

6 Check the diaphragm (B). 7 Mark any indicator of abnormal wear or

failure or damage. 8 Replace the diaphragm (B),

according to the regular maintenance schedule, or if necessary.

A B C

Figure 10.32: Remove the diaphragm




201150-IOM-EN-R03 10.35

Pos: 44.57.11 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/### Assembly: Cleaning after diaphragm leakage @ 5\mod_1231426603303_31.doc @ 45210 @

10.12.2 Cleaning after diaphragm leakage or damage or contamination

INFORMATION

In case of questions or doubt, related to work because of a diaphragm replacement or diaphragm failure, please do not hesitate to contact the service department of Weir Minerals Netherlands b.v.

ATTENTION

After leakage of slurry into the propelling liquid camber, hard particles and chemical influences can result in corrosion and mechanical wear and damage. • Clean as soon as possible the propelling liquid system totally,

to avoid problems as a result of contamination. • Clean and dry all parts immediately after dis-assembly, to avoid sticking of slurry.

Using warm flushing water helps to clean away slurry. Dry all metal surfaces immediately after cleaning.

• The best way to preserve an "out of operation" pump: after cleaning and drying, fill the propelling liquid chamber and the propelling liquid system with fresh propelling liquid.

Diagnosis recommendation:

1 Remove the diaphragm and keep it available for inspection and diagnosis. 2 Drain the oil of the propelling liquid system of the involved diaphragm. 3 Do the oil quality laboratory check.

Decide how to proceed, depending on the level of the contamination of this oil.

Draining and inspection and cleaning of the "Propelling liquid chamber":

1 Inspect the propelling liquid chamber behind the diaphragm. Search for any kind of slurry contamination. Slurry can settle in lower places and get trapped in clearances between parts and in de-aeration holes.

2 Clean and dry and inspect all surfaces. 3 Clean and dry and inspect all de-aeration holes. 4 Clean and dry and inspect all plugs and connections and joints.

Recommendations for a full cleaning procedure:

1 Open and inspect and clean the propelling liquid tank. 2 Clean the propelling liquid chamber, from the diaphragm opening up to the piston. 3 If applicable, then remove and clean the "FILLING RING" in the diaphragm chamber.

Refer to the procedures in the next chapter. 4 Disconnect the propelling liquid lines, inspect them and flush the lines clean. 5 Open and inspect and clean all propelling liquid 2/2 valves at the inlet side and the outlet side. 6 Open and inspect and clean all non-return valves inside the 2/2 valve block. 7 Open and inspect and clean all non-return valves in the piping (near the 2/2 valves). 8 Replace all filters in the suction line and the discharge line of the propelling liquid pump.


10.36 201150-IOM-EN-R03

Draining and inspection and cleaning of the "PRESSURE LIMITATION SYSTEM":

WARNING

At normal conditions, the highest discharge operating pressure of the pump will remain in the piping of the "PRESSURE LIMITATION SYSTEM" between the pressure relieve valve and the non-return valves. • Always discharge the pressure in the piping, by opening the drain valve,

before working at it or at the connecting valves. 1 To de-pressurize this section, open the vent valve at the piping between the pressure-relieve valve and

the non-return valves. 2 To drain the oil in this section, open the plug and collect it in a bucket. 3 If there is contamination in the propelling liquid,

then remove the piping and open and clean and inspect the non-return valve and the safety relief valve.

Inspection and cleaning of the piston and liner:

1 Disassemble and clean and inspect the piston unit and its piston seals. If necessary, then replace the piston seals.

2 Clean and inspect the cylinder liner.

Refer to chapter "Assembly and disassembly", "Piston unit."

Refilling:

1 Replace all the propelling liquid. 2 Replace all propelling liquid suction filters and discharge filters. 3 Re-fill the propelling liquid tank.

Refer to the according chapter for the procedure of replacing the propelling liquid. Refer to document "UTILITY CONSUMPTION LIST" in chapter "Technical data" for the quality and quantity of the propelling liquid.

ATTENTION

Remember at the priming phase to re-fill and de-aerate all the drained piping in the propelling liquid system and pressure limitation system.

Pos: 44.57.12 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/@Overview#MMX+filling ring @ 5\mod_1231429364256_31.doc @ 45228 @


201150-IOM-EN-R03 10.37

Overview



ABCDEFGHI

R





10.38 201150-IOM-EN-R03

Pos: 44.57.14 /GEHO/Heading/H4/Covering ring @ 5\mod_1232024558066_31.doc @ 45423 @

10.12.2.1 Covering ring Pos: 44.57.15 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Filling Ring/@ Remove the cover ring#MMX @ 5\mod_1231346133001_31.doc @ 45142 @

Remove the front initiator housing

Refer to the figure above.

1 Remove the front initiator housing (G). 2 Remove its o-ring. 3 Clean and dry all parts and their thread.

Un-lock the guide bush

Refer to the figure above.

1 Remove the lock screws (2xH) of the guide bush.

Remove the covering ring

Refer to figure 1.

1 Remove the screws (3xE). 2 Use a jaw puller with a special tool, a centre plug (it is included in the tool set "HOISTING TOOL").

Put the centre plug of the jaw puller against the center of the guide bush (F) of the monitoring rod. 3 Put centre plug (C) to monitoring rod guide bush (D).

4 Put the puller jaws behind the covering ring (B).

5 Tighten the jaw puller (A). Use a wrench. If the covering ring is stuck, than use a soft hammer (wood or copper), to knock on the ring.

Refer to figure 2.

6 Remove cover ring (B). 7 Clean and dry all parts and their thread.

1

2

DCA B E

FB

Figure 10.34: Remove the cover ring with a jaw puller




201150-IOM-EN-R03 10.39

Pos: 44.57.17 /GEHO/Heading/H4/#.#.#.# Monitoring rod guide bush @ 1\mod_1165393535316_31.doc @ 9023 @ 4

10.12.2.2 Monitoring rod guide bush Pos: 44.57.18 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Guide bush/@Remove#MMX+filling ring @ 5\mod_1231347147085_31.doc @ 45152 @

1 Remove the guide bush (F). 2 Check the guide bush for wear and

damage. 3 If necessary, than replace the guide bush. 4 Clean and dry all parts.

ABCDEFGHI

R

Figure 10.35:

Pos: 44.57.19 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Filling Ring/#### Remove the filling ring @ 1\mod_1165316258091_31.doc @ 8940 @ 4

10.12.2.3 Remove the filling ring

CAUTION

To avoid injuries and damage of parts: • Use a special lifting tool to handle the filling ring.

1 Check that the guide bush is removed, for else, the tool can not fit at the filler ring.

2 Remove the screws (3xD) from the filling ring. Refer for the locations to the special lifting tool.

3 Screw the special lifting tool (A) to the filling ring (B). If applicable, than use the special jack-off-bolds.

4 Remove the remaining filling ring screws (3xD).

5 Remove the filling ring (B). If applicable, than use the special jack-off-bolds. If the filling ring is stuck, than use a soft hammer (wood or copper) to knock at the outside of the ring.

6 Clean and dry all parts and their thread and the inside of the propelling liquid chamber.

7 Clean and dry (with high pressure air) the de-aeration holes (2x) in the filling ring. Check that they are free and no dirt remains.

A B

Figure 10.36: Removing the filling ring with the lifting tool




10.40 201150-IOM-EN-R03

Pos: 44.57.21 /GEHO/Heading/H3/#.#.# Assembly @ 0\mod_1146735726056_31.doc @ 3610 @

10.12.3 Assembly Pos: 44.57.22 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/ATTENTION Clean all parts @ 5\mod_1231514092064_31.doc @ 45260 @

ATTENTION

After a diaphragm leakage or damage or contamination, before starting the assembly, it is essential to clean and dry all parts.

Refer to chapter "Cleaning after diaphragm leakage or damage or contamination".

Cleaning

1 Check that all cleaning preparations are done properly. 2 Clean and dry the diaphragm housing. 3 Clean and dry all parts. 4 Clean and dry (with high pressure air) the de-aeration holes at the diaphragm housing (1x),

and (if applicable) the filling ring (2x).

CAUTION

Cleaning all de-aeration holes is essential for proper de-aeration.

Pos: 44.57.23 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/@Overview#MMX+filling ring @ 5\mod_1231429364256_31.doc @ 45228 @

Overview



ABCDEFGHI

R





201150-IOM-EN-R03 10.41

Pos: 44.57.25 /GEHO/Heading/H4/Filling ring @ 1\mod_1165326308309_31.doc @ 9003 @

10.12.3.1 Filling ring Pos: 44.57.26 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Filling Ring/Install the filling ring @ 1\mod_1165392370371_31.doc @ 9021 @

Install the filling ring

CAUTION

To avoid injuries and damage of parts: • Use a special lifting tool to handle the filling ring, as shown in the figure.

1 Use the special lifting tool. Check that the filler ring is balanced in the hoist perfectly vertical, to enable easy centering into the housing.

2 Check the position of the filler ring, the de-aeration holes must be on top, as shown in the figure.

3 Move carefully the filling ring (B) into the diaphragm housing.

4 Tighten the filling ring screws (3x). 5 Remove the lifting tool (A). 6 Tighten the remaining filling ring screws

(3x).

A B

Figure 10.38: Install the filling ring with the lifting tool




10.42 201150-IOM-EN-R03

Pos: 44.57.28 /GEHO/Heading/H4/#.#.#.# Monitoring rod guide bush @ 1\mod_1165393535316_31.doc @ 9023 @ 4

10.12.3.2 Monitoring rod guide bush Pos: 44.57.29 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Guide bush/@Install#MMX-binnenschroef+filling ring @ 5\mod_1231347339768_31.doc @ 45162 @

1 Clean and dry all parts. 2 Install the monitoring rod guide bush (F).

Check the position, the hole for the initiator housing must be on top, as shown in the figure.

3 Use at the lock screws (2xH) a nut-lock (like "LOCTITE NUTLOCK 243"). Lock the guide bush with the lock screws (2xH) into the filling ring (A).

Refer to chapter "Tightening torques" to the correct torques.

ABCDEFGHI

R

Figure 10.39:


Pos: 44.57.30 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Filling Ring/Install the covering ring @ 1\mod_1165392147668_31.doc @ 9018 @

10.12.3.3 Install the covering ring

1 Clean and dry all parts. 2 Put the cover ring into the filling ring. 3 Tighten the covering ring screws (3x).

Refer to chapter "Tightening torques" to the correct torques. Pos: 44.57.31 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.43

Pos: 44.57.32 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/#### Assembly of the front initiator housing @ 5\mod_1231428012330_31.doc @ 45219 @

10.12.3.4 Assembly of the front initiator housing

1 Clean and dry all parts. 2 If necessary, then replace the o-ring. 3 Install the o-ring. 4 Install the front initiator housing. Pos: 44.57.33 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/#### Initiator coupling nuts at the diaphragm housings @ 5\mod_1220445788139_31.doc @ 37905 @ 4

10.12.3.5 Initiator coupling nuts at the diaphragm housings

DANGER


The initiator coupling nuts at the diaphragm housings should not be tightened, to avoid heat expansion forces. 1 Screw every initiator coupling nut hand-

tight and then loosen about 45 degrees.

Figure 10.40: Initiator coupling nuts at the diaphragm housings


Pos: 44.57.34 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/#### Function check of the initiators @ 5\mod_1232039717870_31.doc @ 45440 @

10.12.3.6 Function check of the initiators

Check the fill and outlet functions, operated by the monitoring-rod and its magnet moving under the initiators. Triggering of these functions is displayed accordingly at the GEHO panel for each rod.

CAUTION

This function check can be done, with only the GEHO panel in operation, and all other power supply shut-off.

1 Push the monitoring-rod forwards (into the housing), to trigger the fill-function, displayed at the GEHO

panel. 2 Pull the monitoring-rod backwards, to trigger the outlet-function, displayed at the GEHO panel. 3 Proceed only, if this test is perfect repeated 5x. Pos: 44.57.35 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


10.44 201150-IOM-EN-R03

Pos: 44.57.36 /GEHO/Heading/H4/#.#.#.# Monitoring rod @ 6\mod_1233584025586_31.doc @ 46473 @

10.12.3.7 Monitoring rod Pos: 44.57.37 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm/Closed diaphragm/Assembling, Monitoring rod_closed Diaphragm_size > = 10 l. @ 1\mod_1165320506364_31.doc @ 8950 @ Disasse

1 Clean the thread of monitoring rod (C). 2 Clean the threaded pin (B) of the

diaphragm (A). 3 Apply to the threaded pin (B) a nut-lock

(like "LOCTITE NUTLOCK 243"). 4 Screw the monitoring rod (C) to the pump

diaphragm (A).

Refer to chapter "Tightening torques" for the correct torque.

C

B

A

Figure 10.41: Assembling the monitoring rod and diaphragm.

Pos: 44.57.38 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm unit/Hydraulic/#### Install @ 1\mod_1165321911048_31.doc @ 8969 @ 4

10.12.3.8 Diaphragm assembly

1 Clean and dry all parts. 2 Clean the diaphragm area of the

diaphragm housing (A). 3 Grease the clamping edge (C) of the

diaphragm housing (A).

ATTENTION

Use only oil free grease.

4 Install the diaphragm (B) into the

diaphragm housing (A).

A B C

Figure 10.42: Install the diaphragm unit




201150-IOM-EN-R03 10.45

Pos: 44.57.40 /GEHO/Heading/H4/#.#.#.# Diaphragm housing cover @ 1\mod_1165393688115_31.doc @ 9026 @

10.12.3.9 Diaphragm housing cover Pos: 44.57.41 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Install, Hoisting bracket @ 1\mod_1165323498290_31.doc @ 8998 @ 55

Preparation

1 Check the diaphragm housing cover seal. 2 If necessary, then replace the diaphragm

housing cover seal. 3 Apply grease at the seal area of the cover

and the housing. 4 Install the diaphragm housing cover seal.

Mounting

5 Use the "DIAPHRAGM HOUSING COVER HOISTING BRACKET".

Figure 10.43: The "DIAPHRAGM COVER HOISTING

BRACKET"

ATTENTION

6 Make sure that all the push-off bolts (G) at the valve cover (A) are unscrewed and free from any contact with the top of the valve housing. Ensure a metal to metal fit between the valve housing cover and valve housing.

7 Check that the cover is hoisted perfectly vertical. 8 Put the diaphragm housing cover to the diaphragm housing. 9 Secure the diaphragm housing cover with four cover nuts.

Use a wrench. 10 Screw evenly, until the cover sits flat on the housing via its raised face (check for even clearance all

around). 11 Remove the "DIAPHRAGM HOUSING COVER HOISTING BRACKET".

Store it, clean and safe and protected. 12 Tighten all other cover nuts hand-tight. Pos: 44.57.42 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/Diaphragm housing cover/Hydraulic/Tighten, single piston @ 1\mod_1165323465060_31.doc @ 8995 @ 45555


10.46 201150-IOM-EN-R03

10.12.3.10 "HYDRAULIC TENSION RING UNIT"

Preparation

1 Use a special tool, the "HYDRAULIC TENSION RING" (B). Refer to chapter "Special tools".

2 Place the "HYDRAULIC TENSION RING" (B) over the stud bolts. Use an appropriate lifting device. Use the lifting eye (A).

3 Hand-tighten all nuts (C) at the tension ring.

4 Disconnect the protection cap of the hydraulic quick release connector (E).

5 Connect the hose of the "HYDRAULIC PUMP UNIT" to the hydraulic quick release connector (E).

B

AF

D

C

E

Figure 10.44: Install the "HYDRAULIC TENSION RING"

De-aeration procedure (if necessary):

De-aeration is required, if the "HYDRAULIC TENSION RING" (B) is used the first time (= initial use), or if there is air in the hydraulic canals, so during hydraulic pressurizing the hydraulic system is compressible. 1 Remove the blind plug (F), to enable the de-aeration of the tool (B). 2 Activate the "HYDRAULIC PUMP UNIT",

until hydraulic oil with no air bubbles leaks out of the hole (F). 3 Tighten the de-aeration hole with the blind plug (F).

Preparation hydraulic pistons

Legend A Diaphragm housing cover B Hydraulic tension ring unit C Diaphragm housing cover stud bolt D Diaphragm housing cover nut E Pin (to turn the cover nut) F Tension ring nut

A B C D E F

Figure 10.45: "HYDRAULIC TENSION RING"


201150-IOM-EN-R03 10.47

ATTENTION

For a proper procedure, the pistons and tension-ring-nuts (F) and cover-nuts (D) the must be in their start position. All piston heads must be even with the top surface of the "HYDRAULIC TENSION RING" (B). As shown in the figure above.

4 Open the drain valve at the hydraulic pump, to enable the pistons to move.

5 Screw all the tension-ring-nuts (F) into the position, that the nuts bottom surfaces are even with the top surface of the "HYDRAULIC TENSION RING" (B). As shown in the figure above.

If some pistons heads where above the ring surface, then they have been pushed back into their start position by the tension-ring-nuts (F). If some pistons heads are below the ring surface, then they must be pushed back into their start position by the hydraulic pump. 6 Close the drain valve at the hydraulic pump. 7 Activate the "HYDRAULIC PUMP UNIT",

until the hydraulic oil pushed all those pistons against the tension-ring-nuts (F). 8 Check the positions of the piston heads.

Tighten the diaphragm cover nuts

1 Activate the "HYDRAULIC PUMP UNIT", to pressurize the pistons in the "HYDRAULIC TENSION RING".

Refer to chapter "Technical data", "Special torques", "Diaphragm housing unit" for the procedure and torques and pressure.

2 Pre-tighten: Tighten all the diaphragm housing cover nuts (D) with the pin (E), apply normal hand force torque.

3 Release the pressure from the "HYDRAULIC TENSION RING", to allow a settling of the surfaces.

4 Pressurize again the "HYDRAULIC TENSION RING".


5 Final-tighten: Tighten all diaphragm housing cover nuts (D) with the pin (E) with normal hand force torque.


6 Open the drain side of the oil-return/de-aerate valve at the hydraulic pump, to relief the hydraulic pressure at the tensioning ring.

7 Remove all tension ring nuts (F). 8 Disconnect the hydraulic hose. 9 Put the protection cap on the hydraulic quick release connector. 10 Remove the "HYDRAULIC TENSION RING" (B). 11 Install the push-off bolds at the cover.

Pos: 44.57.43 /GEHO/Assembly and Disassembly_during lock-out/Diaphragm housing unit/### De-aerating the propelling liquid chamber @ 5\mod_1231513255148_31.doc @ 45251 @ 3

10.12.4 De-aerating the propelling liquid chamber

ATTENTION

After replacing a diaphragm, it is essential to de-aerate totally the propelling liquid chamber and all connected piping.

Refer to chapter "Start-up, priming procedure". Pos: 44.58 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


10.48 201150-IOM-EN-R03

Pos: 44.59 /GEHO/Technical data sheets/Special torques/Piston unit/H.835.0990.169, drawing T.835.000.190 @ 4\mod_1215432684223_31.doc @ 36754 @

"PISTON UNIT" - 835.0990.169, drawing T.835.000.190 Pos: 44.60.1 /GEHO/Heading/H2/#.# Piston unit @ 0\mod_1152094187891_31.doc @ 5129 @

10.13 Piston unit Pos: 44.60.2 /GEHO/Assembly and Disassembly_during lock-out/Piston unit/TZPM/Overview @ 1\mod_1163689690473_31.doc @ 8653 @

A "PISTON ROD" B "THRUST PIECE" C Threaded bolts D Piston "GUIDE RING" E 2x chevron piston seals

"SET OF ROOF SHAPED RINGS" F Piston "NUT" G "RETAINING PLATE" H "CYLINDER LINER"

A D G HFCB E

Figure 10.46: Piston unit overview Pos: 44.60.3 /GEHO/Heading/H3/#.#.# Disassembly @ 0\mod_1146735769451_31.doc @ 3613 @

10.13.1 Disassembly Pos: 44.60.4 /GEHO/Assembly and Disassembly_during lock-out/Procedures_during lock-out/## Propelling liquid drain/Refer to chapter "Propelling liquid drain" @ 8\mod_1255524757737_31.doc @ 55549 @

Drain the propelling liquid.

Refer to chapter "Propelling liquid drain" for a safe and proper procedure. Pos: 44.60.5 /GEHO/Assembly and Disassembly_during lock-out/Piston unit/TZPM/Disassembly @ 1\mod_1161678281536_31.doc @ 6591 @ 444

10.13.1.1 Preparation

1 Remove the top cover plate of the piston unit. 2 Move the "PISTON UNIT" to the most forward position.

DANGER

Refer to chapter "Manual rotation of the pump crankshaft" for the procedure.

• Before going on, make sure, that the crankshaft is blocked against rotating, to avoid risks during working.

3 Remove the "CLAMPING PIECE" between "PISTON ROD" and "CROSSHEAD ROD". 4 Move the crosshead to the most backward position.

DANGER



5 If applicable, then disconnect the flushing pipes. 6 Remove the lock nuts at the "THRUST PIECE". 7 Remove the upper threaded bolts. 8 Remove the "THRUST PIECE".

10.13.1.2 Secure the piston unit

1 Put a suitable hoisting belt around the piston unit. 2 Make sure that the hoisting belt is NOT below the two lower threaded bolts. 3 Tension the hoisting belt. 4 Turn the crankshaft, to move the "CROSSHEAD" to the most forward position.


201150-IOM-EN-R03 10.49

DANGER



5 Install the "CLAMPING PIECE" between "PISTON ROD" and "CROSSHEAD ROD".

10.13.1.3 Remove the piston unit

Use the special tool "PULLING DEVICE CIL.LINER" (= cylinder liner pulling tool).

1 Place the cylinder liner pulling tool to the piston unit.

2 Pull the piston unit out of the bore, by moving the crosshead backwards.

Figure 10.47:

DANGER



3 Remove the cylinder liner pulling tool. 4 Remove the "CLAMPING PIECE" between

"PISTON ROD" and "CROSSHEAD ROD".

5 Remove the piston unit.

Figure 10.48: Pos: 44.60.6 /GEHO/Assembly and Disassembly_during lock-out/Piston unit/TZPM/Dust cover/### TZPM Crosshead rod-dust cover_replace proc. @ 7\mod_1253878123205_31.doc @ 54739 @ 3445555


10.50 201150-IOM-EN-R03

10.13.2 Replace procedure for the dust cover rings

10.13.2.1 Overview TZPM type

Figure 10.49: TZPM "CROSSHEAD-ROD"


Figure 10.50: TZPM "DUST COVER"


DETAIL "X" = "DUST COVER" A "CROSSHEAD" B "CROSSHEAD ROD" C "CLAMPING PIECE" D 2 flat bars to tighten the

"DUST COVER HOUSING" (XA) E "O-RING DUST COVER HOUSING"

XA "DUST COVER HOUSING" XB "WIPER RING" XC "O-RING" XD "GASKET HOLDER" XE "BOLT" XF "SEALING RING"

10.13.2.2 Replace and align the rings in the "GASKET HOLDER"

Remove the rings in the "GASKET HOLDER"

1 Make sure that the "CLAMPING PIECE" is removed from the "CROSSHEAD ROD", and the "CROSSHEAD" is moved and blocked in its most backward position.

2 Remove the bolts (XE). 3 Remove the "GASKET HOLDER" (XD) from the "CROSSHEAD ROD" (B). 4 Remove the "WIPER RING" (XB) and the "O-RING" (XC) from the "GASKET HOLDER" (XD). 5 Clean the "GASKET HOLDER" (XD).

Assemble the "DUST COVER HOUSING"

(If it was removed, then assemble this first.)

1 Put the O-ring (E) to the "DUST COVER HOUSING" (XA). 2 Slide the "DUST COVER HOUSING" (XA) against the frame unit bulkhead. 3 Tighten "DUST COVER HOUSING" (XA). Use the two flat bars (D).


4 If applicable, then connect the lubrication line to the "DUST COVER HOUSING" (XA).

Preparation of the rings in the "GASKET HOLDER"

1 Make sure that the sealing surfaces of the "GASKET HOLDER" (XD) and the "CROSSHEAD ROD" (B) are free from dirt and dust and corrosion.

2 Check the "WIPER RING" (XB) and the "O-RING" (XC). Replace them, if necessary.

3 Put the "WIPER RING" (XB) and the "O-RING" (XC) into the "GASKET HOLDER" (XD). Grease the rings with the normal lubrication oil.

4 Grease the round surface of the "CROSSHEAD ROD" with the normal lubrication oil. (To protect the rings during sliding on the rod.)

5 Slide carefully and gently the pre-assembled "GASKET HOLDER" (XD) (with its rings and "SEALING RING" XF) on the "CROSSHEAD ROD" (B) against the "DUST COVER HOUSING" (XA).


201150-IOM-EN-R03 10.51

Alignment of the "GASKET HOLDER" and its rings

1 Make sure that the "CROSSHEAD" (A) is in the middle position of its stroke. (To achieve for the alignment of the rings a middle position between the "TOP DEAD END" and the "BOTTOM DEAD END".)

2 Hand-tighten with the bolts the "GASKET HOLDER" (XD) at the "DUST COVER HOUSING" (XA). 3 Make sure that the "GASKET HOLDER" (XD) is proper aligned on the "CROSSHEAD ROD" (B)

(to improve the lifetime and functions of these rings). If necessary, then use the clearance in the bolt-holes of the "GASKET HOLDER" (XD) for alignment.If the "DUST COVER HOUSING" (XA) was dis-assembled, then you may need to re-position it also, to achieve a proper alignment.

4 Tighten the bolts at the "GASKET HOLDER" (XD). Make sure that during tightening, the parts do not change the position and the alignment.


Pos: 44.60.7 /GEHO/Heading/H3/#.#.# Assembly @ 0\mod_1146735726056_31.doc @ 3610 @

10.13.3 Assembly Pos: 44.60.8 /GEHO/Assembly and Disassembly_during lock-out/Piston unit/TZPM/Assembly @ 1\mod_1163689511253_31.doc @ 8647 @ 444

10.13.3.1 Preparation

1 Replace the piston "GUIDE RING", if necessary.

2 If necessary, replace the "CHEVRON"-type piston seals, "SET OF ROOF SHAPED RINGS".

3 Check the "CYLINDER LINER" for grooves. Replace the cylinder liner, if necessary.

4 Lubricate to the "CHEVRON"-type piston seals.

5 Lubricate the "CYLINDER LINER" surface. 6 Put the piston assembly into the

"CYLINDER LINER".

Figure 10.51: Lubrication points

10.13.3.2 Install the piston unit

1 Check the seal ring (A) at the corner-piece / middle-piece. Replace if necessary.

2 Lubricate the seal ring (A) at the corner-piece / middle-piece.

3 Put a hoisting belt to the piston unit (C). 4 Put the piston unit (C) into the cylinder. 5 Put the threaded bolts (B) to the

connection nuts.

A

B

C

Figure 10.52: Install the piston unit


10.52 201150-IOM-EN-R03

10.13.3.3 Final works

1 Install the "THRUST RING". 2 Tighten the lock nuts at the "THRUST PIECE".

Refer to chapter "Special torques" for the correct torque.

3 Install the flushing pipes, if applicable. 4 Move the "CROSSHEAD" forwards.

Make sure the "CROSSHEAD ROD" touches the "PISTON ROD".

DANGER



5 Assemble the "CLAMPING PIECE" at the "CROSSHEAD ROD" and "PISTON ROD".

Refer to chapter "Tightening torques" for the correct torque. Pos: 44.61 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


201150-IOM-EN-R03 10.53

Pos: 44.62 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/H.851.010.110, drawing T.851.000.336 @ 2\mod_1193906054150_31.doc @ 19004 @

"PULSATION DAMPER UNIT" 150/160 = 851.010.110, drawing T.851.000.336 Pos: 44.63.1 /GEHO/Heading/H2/#.# Pulsation dampener @ 1\mod_1168952826922_31.doc @ 11788 @

10.14 Pulsation dampener Pos: 44.63.2 /GEHO/Heading/H3/#.#.# Safety instructions @ 7\mod_1249042333469_31.doc @ 53498 @

10.14.1 Safety instructions Pos: 44.63.3 /GEHO/Assembly and Disassembly_during lock-out/Pulsation damper/Safety instructions/Safety instructions pulsation dampener @ 1\mod_1168953439328_31.doc @ 11799 @

WARNING

The pre-charge pressure may never exceed the maximum allowed pressure, as indicated at the dampener identification plate.

WARNING

The dampener may be under pressure, even when the pressure gauge indicates no pressure. The pressure sensing opening may be clogged.

WARNING

In case of insufficient pre-charge pressure or nitrogen leakage, the pressure pulsations may be excessive and may cause heavy vibrations.

WARNING

• ONLY use nitrogen to pre-charge a dampener. • NEVER use oxygen, because of explosion danger.

WARNING

In case of an external fire, the nitrogen pressure inside the dampener will increase and may exceed the dampener design pressure.

WARNING

In case of a very rapid pressure drop in the discharge line, in combination with dis-location of the dampener diaphragm in relation to the dampener in/outlet opening, a diaphragm rupture might occur. In this case, the nitrogen can enter the slurry line and pressurize a blocked section of this slurry line or form a nitrogen “bubble” under pressure in the slurry line.

WARNING

• Prevent breathing in nitrogen. Escaping nitrogen may cause lack of oxygen.

WARNING

• Prevent breathing in nitrogen. If discharging the gas pressure through the valve, then the escaping nitrogen can push away the air in the direct environment, that can cause lack of oxygen.



10.54 201150-IOM-EN-R03

Pos: 44.63.5 /GEHO/Assembly and Disassembly_during lock-out/Pulsation damper/### Disassembly @ 0\mod_1156236790706_31.doc @ 5737 @ 355

10.14.2 Remove the diaphragm

Preparation

1 Strictly obey the pulsation dampener safety instructions.

Refer to chapter "Pre-charging the discharge pulsation dampener".

2 Open in many short steps the nitrogen filler valve, to discharge the nitrogen gas pressure from the pulsation dampener. Check this at the pressure gauge.

DANGER

Leaking nitrogen (N2) causes lack of oxygen: • Prevent breathing in nitrogen. • Be aware of the risk of suffocation, caused by to much nitrogen in the air. • Prevent nitrogen filling the working environment. • Assure in small rooms good ventilation, because of risks of nitrogen leakage. • Assure free escape routes, because of risks of nitrogen gas.

3 Make sure that the pulsation dampener is depressurized.

4 Loosen the cover nuts only a few turns.

DANGER

• DO NOT remove the cover nuts now. • First make sure that the pulsation dampener cover does not come upward against the

nuts. This indicates that there is still pressure inside the pulsation dampener.

5 Remove the cover nuts. Use the lifting eye and a proper lifting device to remove the cover from the pulsation dampener.

ATTENTION

The lifting eye on the pulsation dampener cover is only suitable • for lifting the cover of the housing and • for lifting the pulsation dampener unit, NEVER for hoisting parts, attached to the bottom of the dampener housing.

Remove the diaphragm

1 Mount a hoisting eye bolt (A) at the bottom of the diaphragm.

2 Hoist at the hoisting eye the pulsation dampener diaphragm out of the housing.

DANGER

Keep away your hands, during this action.

3 Inspect the interior of the pulsation

dampener for signs of abnormal wear.

A

Figure 10.53: Preparation for removal of the diaphragm (The figure shows a general schematic arrangement, applicable for more versions.)



201150-IOM-EN-R03 10.55

Pos: 44.63.7 /GEHO/Assembly and Disassembly_during lock-out/Pulsation damper/### Assemble the diaphragm @ 0\mod_1156228349876_31.doc @ 5731 @ 344

10.14.3 Assemble the diaphragm

1 Clean the surface of the pulsation dampener housing.

2 Clean the surface of the pulsation dampener cover.

3 Make sure to remove all stains and remains from the clamping edges for the diaphragm.

4 Clean the diaphragm clamping edge of the housing.

5 Apply sufficient liquid sealing in the diaphragm clamping edge of the housing.

Figure 10.54: Clamping edge of the diaphragm

INFORMATION

• Recommendation, use the following liquid sealing types to install the diaphragms, O-rings and seals: "Klüber Syntheso Pro AA2, article number 006025".

CAUTION

The liquid sealing is needed for an air-tight sealing between the diaphragm and the metal parts. Failure to properly seal these surfaces may result in a gradual leakage of nitrogen gas and drop of the pre-charge pressure.


10.56 201150-IOM-EN-R03

10.14.3.1 Diaphragm folding, option 1

1 Push the cone outward.

2 Fold the diaphragm.


201150-IOM-EN-R03 10.57

3 Insert the folded diaphragm into the pulsation dampener housing.

4 Move the diaphragm into position.

5 Make sure that the clamping rim fits in the shoulder of the dampener housing.


10.58 201150-IOM-EN-R03

10.14.3.2 Diaphragm folding, option 2

1 Fold the diaphragm.

2 Insert the diaphragm into the pulsation dampener housing.


201150-IOM-EN-R03 10.59

3 Make sure that there is still sufficient sealing grease in the housing edge for the clamping rim of the diaphragm.

Figure 10.55: Clamping edge of the diaphragm

4 Move the diaphragm into its position.

5 Make sure that the clamping rim of the diaphragm fits well in the edge of the dampener housing.

Figure 10.56:



10.60 201150-IOM-EN-R03

Pos: 44.63.9 /GEHO/Assembly and Disassembly_during lock-out/Pulsation damper/### Assemble the cover @ 8\mod_1265121781812_31.doc @ 58921 @ 3

10.14.4 Assemble the cover

1 Apply sufficient liquid sealing to the sealing edges of the diaphragm to the cover.

Figure 10.57: Sealing edge

CAUTION

The liquid sealing is needed for an air-tight sealing between the diaphragm and the metal parts. Failure to properly seal these surfaces may result in a gradual leakage of nitrogen gas and drop of the pre-charge pressure.

INFORMATION

Recommendation, use the following liquid sealing types to install the diaphragms, O-rings and seals:

• "Klüber Syntheso Pro AA2, article number 006025".

2 Put the cover to the housing. Make sure, that the cover does not push or pull at the diaphragm.

3 Tighten the nuts with the correct torque.

Refer to chapter “Special torques”.

Pos: 44.64 /GEHO/Assembly and Disassembly_during lock-out/Nitrogene filling device/## Nitrogen filling device @ 2\mod_1192101182920_31.doc @ 18265 @

10.15 Nitrogen filling device

• Use the nitrogen filling device for the filling of the hydraulic accumulator(s) and/or the pulsation dampener(s).

Refer to the document "INSTRUMENT LIST" for the correct pressure.

Refer to the chapter "Pre-charging the pulsation dampener" for the correct filling of the pulsation dampener(s) and the accumulator(s). Pos: 45 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Appendix: Parts - Lists and drawings (pump section)

201150-IOM-EN-R03 11.1

Pos: 46.1 /GEHO/Heading/H1/#. Appendix: Parts - Lists and drawings (pump section) @ 1\mod_1169571543393_31.doc @ 11982 @

11 Appendix: Parts - Lists and drawings (pump section) Pos: 46.2 /GEHO/Parts lists/## Safety instructions for parts @ 5\mod_1227872607693_31.doc @ 44431 @ 2

11.1 Safety instructions for parts

DANGER

• Use only genuine GEHO parts. • Order parts only with their WEIR-GEHO item number. This is mandatory, to maintain: • the original safety level, in accordance with the applicable regulations, • the warranty accountability, • the general product accountability, • the original product reliability and durability.

Pos: 46.3 /GEHO/Parts lists/## Ordering parts + NOTE - Items with *** @ 1\mod_1165932498812_31.doc @ 9184 @

11.2 Ordering parts

NOTE

If ordering items marked with ***, then specify the quantity.

Ordering and determination of parts:

• Refer to the pump number, as given on the GEHO type plate. Sample: WEIR pump number = GEHO 7201152/3

• Use the same determination, as given in the parts list. Pos: 46.4 /GEHO/Parts lists/814=Pump/Project/## General storage conditions#01= zonder preservation of pumps @ 5\mod_1231168066513_31.doc @ 44886 @ 233355

11.3 General the handling and storage conditions

11.3.1 Refer to the handling and storage instructions with the packing

• Refer to the instructions on the packing or to the documents delivered with the packing. If available, these specific instructions are additional to the general instructions, as mentioned below.

11.3.2 General instructions

ATTENTION

Always store the pumps and their components • under dry conditions, • in a not-aggressive environment, • protected from direct sun light.

11.3.3 Storage of synthetic materials

• Keep the original sealed package closed as long as possible. • Close and seal an opened package as soon as possible. • Protect package and parts against direct sun-light. • Store the parts in their as-manufactured-shape.

Storage of elastomer materials (spare parts):

• Storage temperature between +5°C / +41°F and +35°C / +95°F at about 85% relative humidity.

Storage of polyurethane materials (valve seat rings):

• Storage temperature between +5°C / +41°F and +25°C / +77°F at about 75% relative humidity. Pos: 46.5 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


11.2 201150-IOM-EN-R03



201150-IOM-EN-R03 11.3

Pos: 46.7 /GEHO/Heading/H2/#.# Part list and drawings @ 3\mod_1204008514007_31.doc @ 26365 @ 2

11.4 Part List and drawings Pos: 47 /GEHO/Parts lists/814=Pump/Project/201150-820.587.201150=R03_2011-05-05 @ 11\mod_1295962758296_0.doc @ 80524 @

GEHO TZPM2000 ASSEMBLY DRAWING REVISION: 00

PART LIST NUMBER 820.587.201150

DRAWING NUMBER T.820.201150

REVISION DATE: R03=05.05.2011

ID ITEM NUMBER DESCRIPTION TECHNICAL DETAILS Qty

005 818.080.559AV PULS.DAMPENER FILLING UNIT 1

010 828.950.126Q LUBRICATION UNIT 1

015 828.950.135N FLUSHING UNIT 1

020 828.950.155N VENTLINE UNIT 1

025 831.020.378C VALVE UNIT 3

026 831.020.379D VALVE UNIT 3

030 832.010.279D DIAPHRAGM HOUSING UNIT 1

035 835.099.169C PISTON UNIT 3

050 845.010.456Q FRAME UNIT 1

060 851.010.110T PULSATION DAMPENER UNIT 2

065 853.010.237K PRESS.LIMIT.REGUL.UNIT 1

070 855.010.055AA PRESSURE TRANSMITTER UNIT 1

075 857.010.126Q PROPELLING LIQUID UNIT 1

080 858.010.118N ELECTRICAL UNIT 1

085 895.587.202A ACCESSORIES 1

090 851.010.112F AIR VESSEL UNIT 1

100 814.201150.16 DRIVE UNIT 1

910.150.052 ROUND HEAD GROOVED PIN D1476 R3X10 SS 20

910.150.031 ROUND HEAD GROOVED PIN D1476 R2X8 SS 6

818.030.272 TYPE PLATE SS 1

818.030.257 NAME PLATE-WEIR 5

818.030.140 NAME PLATE-GEHO 2

913.310.052 HEX.SOCKET HEAD CAPSCREW D84A M3X10 SS 12

915.020.008 HEXAGON NUT D934 M3 SS 12


11.4 201150-IOM-EN-R03


201150-IOM-EN-R03 11.5

PULS.DAMPENER FILLING UNIT DRAWING REVISION: 01

PART LIST NUMBER 818.080.559AV

DRAWING NUMBER T.818.080.195


001 922.595.211 THREADED REDUCING PIECE RED-R1/2/R1/4 2

002 922.985.201 BANJO COUPL.W.ONE BOLT P-RSWV 6L/R1/4 2

003 913.003.138 HEX.SOCKET HEAD CAPSCREW D912 M6X35 STL 7

004 929.050.503 PIPE CLAMP 106-PP 7

005 929.050.530 LOCKING SHEET DP1 7

006 922.105.253 STRAIGHT COUPLING P-GV 6S 2

007 922.365.201 BULKHEAD ELBOW COUPLING P-WSV6L 2


009 730.103.005 TUBE R 6X1.5 ***

010 855.100.066 MOUNTING BLOCK 1

011 921.510.343 PRESSURE GAUGE R100/0-25000KPA 2

012 922.155.062 MALE STUD COUPLING GES 12S/R1/2 2

013 921.020.062 VALVE NPT1/2"-PV4NS-SS 2

014 818.030.026 TYPE PLATE 1

015 910.150.029 ROUND HEAD GROOVED PIN D1476 R2X5 1.4305 4

016 922.945.253 STUD STANDPIPE ADAPTOR EGESD 6SR-WD 2

017 922.305.253 EQUAL ELBOW COUPLING P-WV 6S 2

018 922.175.253 MALE STUD COUPLING P-GEV 6SR-WD 1

019 922.945.262 STUD STANDPIPE ADAPTOR EGESD 12S/R1/2-WD 2

020 922.135.062 MALE CONNECTOR GES 12S/1/2NPT 2

021 925.780.610 NIPPLE 1/2"NPT SS 2

022 931.400.223 SEALING RING 22-27-1.5 DIN7603 2

023 922.285.254 BULKHEAD COUPLING P-GSV 6S 4

024 922.745.262 ADJUSTABLE COUPLING EMASD 12SR 2

025 925.800.610 ADAPTOR NPT1/2"BI-G1/2"BU 2


11.6 201150-IOM-EN-R03


201150-IOM-EN-R03 11.7

LUBRICATION UNIT DRAWING REVISION: 01

PART LIST NUMBER 828.950.126Q



001 950.261.864 ELECTRIC MOTOR 0.75KWN1200 1

002 960.010.626 COUPLING KD19-14/24 (STL 1

003 960.020.073 GEAR PUMP 1

004 960.020.621 LANTERN PIECE LA200X111 1

005 816.941.231 SUPPORT 1



008 914.106.196 HEXAGON SCREW D933 M10X25STL-GLV 4

009 917.306.028 WASHER D125A M10 STL-GLV 4

010 921.700.832 SUCTION FILTER-ELEMENT 0050S-125-WP 1

011 911.070.333 STUD D938 M16X40 STL 4

012 917.346.040 LOCK WASHER D9021A M16 STL-GLV 4

013 999.999.000 ARROW=ROTATING DIRECTION 1




017 870.005.112 COVER 1

018 931.030.375 O-RING R120X4 NBR-70SH 1

019 928.860.027 BALL VALVE SK3-28L25 1

020 921.700.417 FILTER HOUSING LPF280GEXXB 1.0 1

021 921.700.836 FILTER ELEMENT 0280D020 BN3HC 1

031 929.050.501 PIPE CLAMP 428-PP 6

033 929.050.531 LOCKING SHEET DP4 16

034 914.003.144 HEXAGON BOLT D931 M6X65 STL 12

047 730.103.101 TUBE R 12 X 2 ***

048 730.103.213 TUBE R 28 X 2 ***

051 922.945.228 STUD STANDPIPE ADAPTOR EGESD 28LR-WD 3

052 922.285.229 BULKHEAD COUPLING P-GSV 28L 3

054 922.155.228 MALE STUD COUPLING P-GEV 28LR 2

057 922.305.228 EQUAL ELBOW COUPLING P-WV 28L 3


11.8 201150-IOM-EN-R03


058 922.595.230 THREADED REDUCING PIECE RED-R1.1/4-WD/R1 2

059 922.805.228 NON-RETURN VALVE P-RV 28L 374069 1

061 922.455.228 EQUAL TEE COUPLING P-TV 28L 12

062 922.975.231 REDUCING FITTING P-REDVD 28/12L 12


067 828.500.508 BANJO COUPLING 5

068 828.500.509 STUD ADAPTOR 6

069 922.035.228 PROFILE RING P-R 28L 2

070 922.015.229 NUT M 28L 2

071 868.053.287 ORIFICE 3

072 868.053.288 ORIFICE 5

073 868.053.286 ORIFICE 3

074 922.915.228 ADJUST. MALE STUD ELBOW P-EWVD 28L 6

080 915.003.040 HEXAGON NUT D934 M16 STL 4

081 922.935.228 ADJ.MALE T.-STUD P-ELVD 28L 2

083 922.435.209 FEMALE CONNECTOR SNV 12L 1

084 922.950.950 MANOMETER COUPLING MAV12L/1/2"NPT-SS 1

091 922.095.228 BLANKING PLUG VS 28L 1


100 971.600.008 FLOW SENSOR 1

101 922.950.879 T-PIECE E40080/QL28-18-28 1

102 922.950.880 ADAPTER E40104 1


201150-IOM-EN-R03 11.9

FLUSHING UNIT DRAWING REVISION: 00

PART LIST NUMBER 828.950.135N



001 922.945.209 STUD STANDPIPE ADAPTOR EGESD 12L/R1/4-WD 9





006 730.103.108 TUBE R 18 X 1.5 ***



009 730.103.101 TUBE R 12 X 2 ***


012 922.365.219 BULKHEAD ELBOW COUPLING P-WSV 18L 1


11.10 201150-IOM-EN-R03


201150-IOM-EN-R03 11.11

VENTLINE UNIT DRAWING REVISION: 00




001 928.370.305 BANJO COUPL.W. ONE BOLT R3/8"- 8X6 1

002 770.528.000 HOSE ***

003 928.130.005 MALE CONNECTOR ACK- 3/8"-6 4


006 730.103.101 TUBE R 12 X 2 ***

008 922.880.000 NON-RETURN VALVE P-RV 12L(0.5 1


013 928.120.008 MALE CONNECTOR 3/8" - 6 3

014 922.935.209 ADJ.MALE STUD T-STUD B.T P-ELVD 12L 3



11.12 201150-IOM-EN-R03


201150-IOM-EN-R03 11.13

VALVE UNIT DRAWING REVISION: 00

PART LIST NUMBER 831.020.378C



001 023.582.027 VALVE HOUSING 1

003 025.582.031 VALVE COVER 1

010 831.350.127.37 CONICAL VALVE 1

011 831.700.924 VALVE RING 1

012 831.150.919 VALVE SEAT 1

013 831.900.059.14 LOCK NUT 1

014 825.107.036 COMPRESSION SPRING 1

015 831.900.831 CLAMPING PIECE 1

016 831.900.824 GUIDE BUSH 1

017 862.007.540 STUD BOLT 4

018 831.900.715 PISTON 4

019 831.900.717 NUT 1.7225V 4

020 831.900.716 NUT 1.0503KG 4

021 822.270.004.67 SEALING RING 1

022 931.191.200 SEALING RING B7A,224X258WN101 2

024 862.050.191 NUT NF M42 4

026 960.010.613 CONNECTING NIPPLE R1/4"/2000 BAR 2

027 960.010.621 ADAPTER R1/4"XR1/4"-3000B 2

038 931.030.885 O-RING R245X4 NBR70-SH 2

039 933.111.066 ROD SEAL S8-65-75 4

040 933.111.086 ROD SEAL S8-85-100 4

041 913.020.241 HEX.SOCKET HEAD CAPSCREW D912 M12X50 SS 4

042 914.300.040 EYE BOLT D580 M16 1.0401 1

043 914.206.411 HEXAGON SCREW D561A M20X120 STL 2

045 831.900.870 SPACER 1


050 862.007.363 STUD BOLT 12

051 862.050.013.36 NUT 12


11.14 201150-IOM-EN-R03


201150-IOM-EN-R03 11.15

VALVE UNIT DRAWING REVISION: 01

PART LIST NUMBER 831.020.379D



001 023.582.029 VALVE HOUSING 1

003 025.582.033 VALVE COVER 1

010 831.350.127.37 CONICAL VALVE 1

011 831.700.924 VALVE RING 1

012 831.150.919 VALVE SEAT 1

013 831.900.059.14 LOCK NUT 1

014 825.107.036 COMPRESSION SPRING 1


016 831.900.824 GUIDE BUSH 1

017 862.007.539 STUD BOLT 4

018 831.900.715 PISTON 4

019 831.900.717 NUT 1.7225V 4

020 831.900.716 NUT 1.0503KG 4

021 822.270.004.67 SEALING RING 1


027 960.010.621 ADAPTER R1/4"XR1/4"-3000B 2

028 931.400.361 SEALING RING 36-42-2 DIN7603 1

029 831.900.454 PLUG 1

038 931.030.885 O-RING R245X4 NBR70-SH 2

039 933.111.066 ROD SEAL S8-65-75 4

040 933.111.086 ROD SEAL S8-85-100 4


042 914.300.040 EYE BOLT D580 M16 1.0401 1

043 914.206.411 HEXAGON SCREW D561A M20X120 STL 2

045 831.900.871 SPACER 1


050 862.007.542 STUD BOLT 12

051 862.050.129 NUT 12

052 931.190.200 SEALING RING B7A,214X285DIN2697 1


11.16 201150-IOM-EN-R03


201150-IOM-EN-R03 11.17

DIAPHRAGM HOUSING UNIT DRAWING REVISION: 00

PART LIST NUMBER 832.010.279D



002 039.582.041 DIAPHRAGM HOUSING COVER 3

003 045.587.014 DIAPHRAGM HOUSING 3

004 832.101.257 CORNER PIECE 1

005 832.101.259 MIDDLE PIECE 1

006 832.101.258 CORNER PIECE 1

007 832.100.576 RING 1.0503N 3

008 832.100.577 COVERING RING 1.0503N 3

010 828.551.756 SUCTION ELBOW 3

012 862.005.369 INITIATOR HOUSING 1.4301 6

013 832.100.737 COVER 1.0570 6

015 832.100.874 MONITORING ROD 3

016 832.100.624 CLAMPING BUSH 3

019 824.080.018 DIAPHRAGM 3

021 922.085.217 BLANKING END VS-M18X1.5WD 2

022 925.530.224 HEXAGON HEAD PIPE PLUG G 1" DIN 910-5.8 3

023 922.075.209 PLUG VS-R1/4WD 3

030 822.800.004 SEALING RING 3

031 931.031.267 O-RING R55X3 NBR-90SH 6


034 822.250.013 SEALING RING 3

036 931.400.331 SEALING RING 33-39-2 DIN7603 3

037 862.007.458 STUD BOLT 1.7225V 72

038 862.007.550 STUD BOLT 12

039 862.007.587 STUD BOLT 48

040 862.050.129 NUT 48

042 862.007.712 STUD BOLT 36

043 862.050.325 NUT 36

045 862.050.205 NUT NV M56/D2510 72

046 862.050.012.36 NUT 12

049 862.005.803 HEX.HEAD SCREW 1.4404 6


11.18 201150-IOM-EN-R03



052 914.206.420 HEXAGON SCREW D561AM20X220ST-GLV 18

053 816.020.415 PROTECTING RING 3

059 914.103.328 HEXAGON SCREW D933 M16X90 STL 18



068 917.213.135 SPRING TYPE STRAIGHT PIN R6X20 DIN1481 12

070 921.050.001 NEEDLE VALVE G3/8"-UBEL717 3





201150-IOM-EN-R03 11.19

PISTON UNIT DRAWING REVISION: 00

PART LIST NUMBER 835.099.169C



001 063.587.000 PISTON ROD 1.7225V 1

002 841.260.023 CYLINDER LINER 1

003 835.160.018 PISTON BODY 1

004 835.360.014 RETAINING PLATE 2

005 862.008.039 STUD BOLT 6

006 915.040.059 HEXAGON NUT NF M27 DIN2510 6

007 841.900.371 THRUST PIECE 1

009 931.031.452 O-RING R40.64X5.33 NBR-90 1

010 862.050.127 NUT NF M48/D2510 1


012 835.900.190 GUIDE RING 1

015 914.300.040 EYE BOLT D580 M16 1.0401 1

020 933.160.274 SET OF ROOF SHAPED RINGS L=33.5/EK 1

021 933.160.273 SET OF ROOF SHAPED RINGS L=38.7 / EK 1

022 931.031.672 O-RING R328.5X7 NBR90SH 1

023 933.355.335 SUPPORTING RING 335.4-347-2.8STA 1


11.20 201150-IOM-EN-R03


201150-IOM-EN-R03 11.21

FRAME UNIT DRAWING REVISION: 00




001 002.587.013 FRAME 1

003 018.632.001 DISC 1.7225V 12

005 066.587.001 CROSSHEAD PIN SAE 3311 3

006 068.587.004 CONNECTING ROD 3

008 072.587.001 CRANKSHAFT 1

010 081.587.007 BEARING COVER 1

013 086.387.001 PRESSURE PLATE 1

014 081.587.006 BEARING COVER 1

015 088.387.001 PRESSURE PLATE 3

016 090.587.001 CROSSHEAD GUIDE 6

018 089.587.000 CROSSHEAD ROD 3

019 005.587.001 FRAME COVER 1

020 816.955.463 LOCKING PLATE 3

030 931.030.705 O-RING R800X7 NBR-70SH 2

031 823.030.042 SEAL 1

034 823.051.052 SEAL 2

035 823.030.043 SEAL CR-SPONS 3

036 839.100.049 CROSSHEAD 3

037 823.030.028 SEAL 3


039 870.001.231 COVER STL 2

040 870.001.230 COVER STL 1

041 870.001.196 COVER 2

042 822.020.120 SEALING RING 3

044 870.001.226 COVER 3

045 931.030.860 O-RING R608.8X7 NBR-70SH 3



062 914.236.529 HEXAGON SET SCREW D561A M30X2X100STL 4

063 913.003.529 HEX. CAP SREW M30X100 D912 6


11.22 201150-IOM-EN-R03







080 933.101.126 U-RING T20/125-145-16 3

081 933.021.125 WIPER RING 125-137-11NBR-90SH 3

082 911.040.524 STUD BOLT D939 M30X65 STL 22


086 915.006.063 HEXAGON NUT D934 M30 STL-GLV 22

087 913.003.449 HEX.SOCKET HEAD CAPSCREW M24X100 D912 18

089 822.160.023 SEALING RING 3

091 846.100.189 DUST COVER HOUSING 3

092 846.100.126 GASKET HOLDER 3

094 815.812.312 FLAT BAR STEEL 6

095 911.040.321 STUD BOLT M16X50 DIN939-8.8 12

118 935.022.440 LIPSEAL WAS440-480-20 1

121 925.546.145 HEXAGON HEAD PIPE PLUG 3

126 942.900.119 SPHERICAL ROLLER BEARING 2

127 942.900.091 CYL.ROLLER BEARING 3

128 942.900.064 CYLINDER BEARING 3

129 942.410.996 PRESSURE SLEEVE 2

131 922.155.211 MALE STUD COUPLING P-GEW 12L/R1/2 6

132 730.103.103 TUBE R 12 X 1.5 ***

134 925.720.284 PIPE NIPPLE D2982 G2"X250 STL 1

136 921.150.071 GATE VALVE G2" ECON3290 1

138 948.790.002 OILGLASS G2 2

140 921.700.033 FILTER PI 0114 MIC 2

141 942.800.792 LOCK NUT HM3092 1

142 816.955.464 LOCK WASHER 1

143 925.016.114 BEND G3/4"-N1 1

144 917.303.034 WASHER D125A M12 STL 14




201150-IOM-EN-R03 11.23



152 917.500.063 RETAINING RING DUBO M30 2

153 922.075.218 PLUG VS-R1/2WD 1

155 921.200.026 BALL VALVE G2"-ERIKS 3185 1

156 925.526.145 DOUBLE NIPPLE N280 G2 2

157 828.500.559 PIPE NIPPLE 1

158 925.206.145 ELBOW N90 G2 1


11.24 201150-IOM-EN-R03


201150-IOM-EN-R03 11.25

PULSATION DAMPENER UNIT DRAWING REVISION: 00

PART LIST NUMBER 851.010.110T



001 851.500.278 COVER 1

002 851.300.275 PULSATION DAMPENER BODY 1

006 824.040.008 DIAPHRAGM 1

009 862.007.424 STUD BOLT 16

010 922.075.218 PLUG VS-R1/2WD 2

012 914.300.063 RING BOLT D580 M30 C15 1


014 862.050.237 NUT SA194-2H/M36 16

017 818.030.271 TYPE PLATE SS 1

018 818.030.210 TEXT PLATE 1


020 851.500.272 FLANGE A322-GR4140 1

021 931.030.542 O-RING R159.2X5.7NBR-70SH 1

025 822.150.021 SEALING RING 1

028 922.075.209 PLUG VS-R1/4WD 1


11.26 201150-IOM-EN-R03


201150-IOM-EN-R03 11.27

PRESS.LIMIT.REGUL.UNIT DRAWING REVISION: 00

PART LIST NUMBER 853.010.237K



001 921.300.583 SAFETY VALVE 1

002 853.010.259 NON-RETURN VALVE UNIT 3

003 828.551.906 CONNECTING PIPE 1


005 862.015.237 THREADED ROD 8.8-VERZ 24


007 853.100.607 CONNECTING BLOCK 1

008 911.070.569 STUD BOLT D938 M33X100 STL 8



011 816.930.382 RING 1.0503N 1

012 911.070.532 STUD BOLT D938 M30X130 STL 6


014 828.551.678 DRAIN LINE 1



017 822.100.024 SEALING RING 1

018 816.930.373 RING 1

019 822.150.023 SEALING RING R150-R212-2 C4430 2


021 922.075.218 PLUG VS-R1/2WD 1

022 922.945.261 STUD STANDPIPE ADAPTOR EGESD 12SR-WD 2

023 922.455.060 EQUAL TEE COUPLING TS 12S 1

024 921.050.001 NEEDLE VALVE G3/8"-UBEL717 1

025 730.103.101 TUBE R 12 X 2 ***


027 922.015.261 NUT M 12S 2

028 922.035.209 PROFILE RING P-R 12L/S 2

030 921.520.043 SHOCK ABSORBER 1/2"NPT ECON1389 1



11.28 201150-IOM-EN-R03


032 922.075.213 PLUG VS-R3/8WD 1

033 929.050.500 PIPE CLAMP 112-PP 1


035 914.103.139 HEXAGON BOLT D933 M6 X40 STL 1

036 862.015.296 THREADED ROD 2


201150-IOM-EN-R03 11.29

NON-RETURN VALVE UNIT DRAWING REVISION: 00




001 853.100.561 VALVE HOUSING 1.7225V 1

002 853.100.560 VALVE GUIDE 1.7225V 1

003 853.100.559 VALVE 1.7225V 1

004 821.025.050 RING 1

005 821.025.048 RING 1.0503N 1

006 917.800.018 COMPRESSION SPRING R40X3.2X82 1

007 913.006.167 HEX.SOCKET HEAD CAPSCREW D912 M8X30 STL-GLV 4

008 931.030.375 O-RING R120X4 NBR-70SH 1


11.30 201150-IOM-EN-R03


201150-IOM-EN-R03 11.31

PRESSURE TRANSMITTER UNIT DRAWING REVISION: 01

PART LIST NUMBER 855.010.055AA



001 971.450.059 PRESSURE TRANSMITTER 1



004 922.135.211 MALE CONNECTOR P-GEV 12L/1/2NPT 3


006 914.900.019 HEXAGON SCREW 1/4"-20UNC/L=1/2 6

007 921.520.043 SHOCK ABSORBER 1/2"NPT ECON1389 1

008 816.941.166 SUPPORT 1

009 816.941.167 SUPPORT 1

010 914.106.135 HEXAGON SCREW D933 M6X20 STL-GLV 4



11.32 201150-IOM-EN-R03


201150-IOM-EN-R03 11.33

PROPELLING LIQUID UNIT DRAWING REVISION: 00




001 950.261.864 ELECTRIC MOTOR 0.75KWN1200 1

002 960.010.626 COUPLING KD19-14/24 (STL 1

003 960.020.063 GEAR PUMP (R SF2/6 RD-12L 1

004 960.020.621 LANTERN PIECE LA200X111 1

005 816.940.742 SUPPORT 1.0067 1





010 911.070.236 STUD D938 M12X25 STL 2



013 999.999.000 ARROW=ROTATING DIRECTION 1






019 922.295.220 STRAIGHT REDUCT.COUPLING P-GV 18/12L 374536 1

020 921.700.411 FILTER HOUSING LPF240GEXXB 1.0 1

021 921.700.831 FILTER ELEMENT 0240D020BN3HC 1

022 922.365.219 BULKHEAD ELBOW COUPLING P-WSV 18L 1

023 922.435.217 FEMALE CONNECTOR SNV 18L 372943 1

024 922.880.001 NON-RETURN VALVE P-RV 18L(O.5 2



028 922.935.217 ADJ.MALE T.-STUD P-ELVD 18L 3


033 922.105.228 STRAIGHT COUPLING P-GV 28L 1



11.34 201150-IOM-EN-R03



036 922.595.228 THREADED REDUCING PIECE RED-R1.1/4/R1/2 2



039 922.155.061 MALE STUD COUPLING GES 12SR 6

040 973.000.012 HYDR. ACCUMULATOR 6L-330BAR 1

041 922.285.061 BULKHEAD COUPLING GSS 12S 9


049 971.400.045 SILENCER R1/4 8

050 972.200.065 3/2 WAY VALVE NW6-24VDC-NO 6

055 972.200.066 3/2 WAY VALVE NW6-24VDC-NC 2

056 972.900.000 MOUNTING BLOCK R3/'8"-R1/4"-N=8 1

057 925.470.209 DOUBLE NIPPLE N245 G1/2"X3/8"STL 1

058 925.206.110 ELBOW N90 G1/2" MALL.CI 1



061 922.595.219 THREADED REDUCING PIECE RED-R3/4R1 1

063 922.015.261 NUT M 12S 24



066 922.745.209 ADJUSTABLE COUPLING EMASD 12LR 1

067 929.050.500 PIPE CLAMP 112-PP 1



070 853.010.250 PROP.LIQUID/FLUSH.UNIT 1

071 928.370.304 BANJO COUPL. W.ONE BOLT R1/4"- 8X6 8

072 770.528.000 HOSE ***

073 922.075.213 PLUG VS-R3/8WD 3



078 928.110.305 MALE CONNECTOR G1/4"-8X6 8

080 925.800.603 ADAPTOR NPT 1/4"BI-G1/4"BU 1

081 925.800.610 ADAPTOR NPT1/2"BI-G1/2"BU 1



201150-IOM-EN-R03 11.35


083 931.400.142 SEALING RING 14-18-1.5 DIN7603 1

090 928.860.019 3/2 BALL VALVE BK3-18L13 1

091 922.015.219 NUT M 18L 1

092 922.035.217 PROFILE RING P-R 18L 1

096 922.915.060 ADJUST. MALE STUD ELBOW EWSD 12S 3

100 971.600.008 FLOW SENSOR 1

101 922.950.882 T-PIECE E40078/QL18-18-18 1

102 922.950.880 ADAPTER E40104 1

125 928.900.678 H.P. HOSE 1ST25A05A05-650 1

149 925.546.145 HEXAGON HEAD PIPE PLUG 1

150 816.310.104 TANK 1

151 815.010.648 DRIP PAN 1

152 948.790.105 LEVEL INDICATOR SNA254B-S-T-12 1

153 775.542.272 SEAL 12X8 ***

154 925.526.145 DOUBLE NIPPLE N280 G2 3

155 921.200.026 BALL VALVE G2"-ERIKS 3185 1

156 925.530.224 HEXAGON HEAD PIPE PLUG G 1" DIN 910-5.8 1




161 870.005.112 COVER 1

162 931.030.375 O-RING R120X4 NBR-70SH 1


164 921.700.832 SUCTION FILTER-ELEMENT 0050S-125-WP 1


170 815.010.750 PI SKID 1

171 868.001.841 DISTANCE BUSHING 3



174 816.940.820 SUPPORT 2

175 868.001.936 DISTANCE BUSHING 1

176 914.300.040 EYE BOLT D580 M16 1.0401 2


178 914.006.324 HEXAGON BOLT D931 M16X65STL-GLV 1


11.36 201150-IOM-EN-R03


179 915.336.047 HEXAGON NUT D439 B-M20X1.5 3

185 925.206.145 ELBOW N90 G2 2

186 929.300.020 CONNECTING PIECE G2"/633-F/SS 2

187 770.556.578 HOSE TW50-NBR/CR-S ***

188 929.000.531 HOSE BAND CLAMP S62/20SKZ 2

189 929.300.000 COUPLING G2"/633-C/SS 2

191 730.103.108 TUBE R 18 X 1.5 ***

193 730.103.001 TUBE R 6 X 1 ***

194 730.103.101 TUBE R 12 X 2 ***

195 814.201150.50 PIPE R28X2/L=950 1

196 917.950.030 BOLT ADAPTER M16-GLV 4

210 816.020.474 PROTECTION COVER 1

211 911.170.325 HEXAGON SOCKET SET SCREW 1

212 915.020.040 HEXAGON NUT D934 M16 1.4301 1

213 917.850.040 WASHER D125B M16 1.4401 2

214 917.040.040 SPRING WASHER B16 D127B-W1.4401 2



250 770.558.317 HOSE R35-R25 ***

251 929.050.501 PIPE CLAMP 428-PP 1



254 922.985.228 BANJO COUPL. W. ONE BOLT P-RSWV 28LR 2

255 922.950.948 FEMALE METRIC 1

256 922.950.949 FEMALE SWEPT ELBOW 1

257 929.000.012 CLAMP 2


201150-IOM-EN-R03 11.37

PROP.LIQUID/FLUSH.UNIT DRAWING REVISION: 00




001 853.010.241 2/2 WAY VALVE (PA 7

002 853.100.329 VALVE SEAT 7

003 853.100.455 NON-RETURN VALVE 3

004 931.032.051 O-RING R21X1.5 FPM-80SH 11

005 853.100.525 DISTRIBUTOR BLOCK 1

006 862.005.314 BANJO BOLT (R8 4

007 931.082.021 MULTISEAL SCPP45-D 7

008 853.100.323 BASE PLATE 3

009 853.100.330 PLUG 3


012 822.030.024 SEALING RING 8

014 853.010.243 2/2 WAY VALVE (HV9 1

015 853.100.535 DISTRIBUTOR BLOCK 1

016 862.005.396 BANJO BOLT (R3 3

017 853.100.520 BOTTOM PLATE 1

018 853.100.518 PLUG 1

019 853.100.519 VALVE SEAT 1

020 853.100.517 VALVE 1

021 931.082.017 MULTISEAL SCPP45-C 7


11.38 201150-IOM-EN-R03


201150-IOM-EN-R03 11.39

2/2 WAY VALVE (PA) DRAWING REVISION: 01




001 853.100.387 SLIDE BEARING 1

002 921.700.030 FILTER G1/4"-LO.0304-01 1

003 853.100.490 COVER 1

004 853.100.216.64 DAMPENING 1

005 933.500.001 DIAPHRAGM BFA70/60-40 1


008 853.100.385 VALVE HOUSING 1

009 825.102.000.32 COMPRESSION SPRING 1

011 853.100.388 SLIDE BEARING 1

012 917.403.030 RETAINING RING D472 R30X1.2 SS 1

013 933.107.023 U-RING 20-30-8 1

014 853.100.391 VALVE SPINDLE 1


11.40 201150-IOM-EN-R03


201150-IOM-EN-R03 11.41

2/2 WAY VALVE (HV9) DRAWING REVISION: 01




001 853.100.387 SLIDE BEARING 1

002 921.700.030 FILTER G1/4"-LO.0304-01 1

003 853.100.490 COVER 1

004 853.100.216.64 DAMPENING 1

005 933.500.001 DIAPHRAGM BFA70/60-40 1


008 853.100.385 VALVE HOUSING 1

009 825.102.000.32 COMPRESSION SPRING 1

011 853.100.388 SLIDE BEARING 1

012 917.403.030 RETAINING RING D472 R30X1.2 SS 1

013 933.107.023 U-RING 20-30-8 1

014 853.100.522 VALVE SPINDLE 1


11.42 201150-IOM-EN-R03


201150-IOM-EN-R03 11.43

ELECTRICAL UNIT DRAWING REVISION: 01




001 814.201150.34 MEMORY CARD 1

001 814.201150.37 HMI-PANEL 1

001 814.201150.41 CONTROL BOX CPL 1

002 814.201150.40 TERMINAL BOX 1

003 814.201150.42 TERMINAL BOX 1

004 913.306.074 HEX.SOCKET HEAD CAPSCREW D84A M4X16 STL-GLV 4

005 858.100.063 INITIATOR 6

006 931.080.085 U-SEAL 8.5-13.4-1.0 4

007 913.400.165 HEX.SOCKET HEAD CAPSCREW D912 M8X20 1.4401 4

008 915.140.025 HEXAGON NUT D934 M8 SS 4

009 917.280.025 WASHER D125A M8 SS 4

010 816.941.265 CABLE DUCT 1


012 995.025.023 BEND PG13 H318 6

013 995.001.050 HOSE SWIVEL PG 13 12

014 790.000.014 PROTECTION SLEEVE INS.RO.14.5 ***

015 790.000.009 PROTECTION SLEEVE R10 ***

016 795.000.449 CABLE ***

017 995.001.052 HOSE SWIVEL PG 9 1

018 995.025.021 BEND PG9 H318 1

019 995.006.422 ADAPTER 3

020 995.000.124 CABLE GLAND PG11 - H183 3

021 795.000.445 CABLE OELFLEX 2X0.75 MM2 ***

022 995.006.421 ADAPTER M20X1.5/PG9 1

023 730.103.202 TUBE R 22 X 2 ***

024 929.050.502 PIPE CLAMP 322-PP 5


026 914.106.139 HEXAGON SCREW D933 M6X40 4

027 914.106.141 HEXAGON BOLT D933 M6X50 8

028 971.100.055 INITIATOR NI12U-EM18-AP6X 1


11.44 201150-IOM-EN-R03


029 929.000.920 CLAMPING RING 1

030 868.005.011 DETECTOR PIECE 1

031 816.941.261 SUPPORT 1

032 862.050.277 HEXAGON SUPPORT 2

033 816.941.141 SUPPORT 1

034 911.040.321 STUD BOLT M16X50 DIN939-8.8 2



037 995.001.086 CABLE GLAND 1

038 995.000.190 CABLE GLAND 1

039 790.000.013 PROTECTION SLEEVE ***

040 995.040.010 CABLE TIERAP T 50 R 100

041 995.040.012 CABLE TIERAP 4X140 / NYLON 6.6 100

042 795.000.461 CABLE ***

043 858.100.194 CABLE DUCT 1

044 858.100.286 CABLE DUCT 1

045 858.101.004 CABLE CHANNEL 1





050 858.100.244 REDUCER 1.4404 6

051 995.025.022 BEND PG11 3


201150-IOM-EN-R03 11.45

ACCESSORIES DRAWING REVISION: 00

PART LIST NUMBER 895.587.202A



001 815.010.808 BASE FRAME 1

002 828.552.031 PRESSURE PIPE 1

003 828.552.033 SUCTION LINE 1

004 828.552.084 SUPPORT 1

005 828.500.557 PLUG 1

006 931.400.640 SEALING RING 64-72-2.5 D7603 1

007 911.040.690 STUD BOLT D939 M42X110STL 8


009 816.941.245 SUPPORT 2


011 868.002.254 BLINDFLANGE 1

012 931.190.250 SEALING RING B7A-264X345 2

013 862.007.428 STRETCH BOLT 1.7225V 12

014 915.040.073 HEXAAAGON NUT NF M39 DIN2510 36

015 862.007.483 STUD BOLT 1.7225V 12

016 868.002.249 BLINDFLANGE 1

017 822.320.012 SEALING RING 2



020 822.200.023 SEALING RING 3


022 862.007.263 STUD BOLT 16

023 915.040.078 HEXAGON NUT NF M52 DIN2510 16

024 816.930.454 SHIM 3


026 816.930.437 SHIM 3


028 914.236.529 HEXAGON SET SCREW D561A M30X2X100STL 6


030 915.020.040 HEXAGON NUT D934 M16 1.4301 4


11.46 201150-IOM-EN-R03


031 917.280.040 WASHER D125A M16 1.4401 4



201150-IOM-EN-R03 11.47

AIR VESSEL UNIT DRAWING REVISION: 00

PART LIST NUMBER 851.010.112F



001 851.300.324 SUCTION AIR VESSEL 1

002 818.030.142 NAME PLATE-GEHO 1

003 927.020.150 BLIND FLANGE 6"-150LBS 1

004 822.150.050 GASKET R154-R216-2 1


006 818.030.249 TEXT PLATE 1

007 818.030.248 TEXT PLATE 1

008 910.150.031 ROUND HEAD GROOVED PIN D1476 R2X8 SS 8

009 929.050.500 PIPE CLAMP 112-PP 4



012 922.755.062 MANOMETER COUPLING MAS 12SR 1



015 730.103.103 TUBE R 12 X 1.5 ***

016 922.075.218 PLUG VS-R1/2WD 3

017 922.015.261 NUT M 12S 1

019 922.985.210 BANJO COUPL. W. ONE BOLT P-RSWV 12LR 1



022 922.135.217 MALE CONNECTOR P-GEV 18L/1/2NPT 1



11.48 201150-IOM-EN-R03


201150-IOM-EN-R03 11.49

DRIVE UNIT DRAWING REVISION: 00




001 814.201150.31 GEAR BOX 1

002 814.201150.32 FLEX.COUPLING 1

003 814.201150.33 GEAR COUPLING 1

004 814.201150.30 ELECTRIC MOTOR 1549KWN1181 1

005 814.201150.38 FREQUENCY-CONVERTER ACS1014-W1-P5-00 1

006 814.201150.39 TRANSFORMER CTMP 7HA 2100 1

007 815.010.791 BASE FRAME 1

008 816.020.581 PROTECTIVE CAP 1

009 816.020.582 PROTECTIVE CAP 1





014 914.236.533 HEXAGON SET SCREW M30X2X140 D561A-ST 8

015 914.206.328 HEXAGON BOLT D561AM16X90STL-GLV 8


017 915.020.040 HEXAGON NUT D934 M16 1.4301 4


019 917.280.040 WASHER D125A M16 1.4401 4

020 816.930.487 SHIM 2

021 816.930.486 SHIM 2

022 816.930.488 SHIM 4



026 914.106.773 HEXAGON BOLT D933M48X140STL-GLV 4


028 914.206.325 HEXAGON SCREW D561AM16X70STL-GLV 4


Appendix: Parts - Lists and drawings (special tools)

201150-IOM-EN-R03 12.1

Pos: 49.1 /GEHO/Heading/H1/#. Appendix: Parts - Lists and drawings (special tools) @ 1\mod_1169571568190_31.doc @ 11986 @

12 Appendix: Parts - Lists and drawings (special tools) Pos: 49.2 /GEHO/Parts lists/## Safety instructions for parts @ 5\mod_1227872607693_31.doc @ 44431 @ 2

12.1 Safety instructions for parts

DANGER

• Use only genuine GEHO parts. • Order parts only with their WEIR-GEHO item number. This is mandatory, to maintain: • the original safety level, in accordance with the applicable regulations, • the warranty accountability, • the general product accountability, • the original product reliability and durability.

Pos: 49.3 /GEHO/Parts lists/## Ordering parts + NOTE - Items with *** @ 1\mod_1165932498812_31.doc @ 9184 @

12.2 Ordering parts

NOTE

If ordering items marked with ***, then specify the quantity.

Ordering and determination of parts:

• Refer to the pump number, as given on the GEHO type plate. Sample: WEIR pump number = GEHO 7201152/3

• Use the same determination, as given in the parts list. Pos: 49.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 @


12.2 201150-IOM-EN-R03



201150-IOM-EN-R03 12.3

Pos: 49.6 /GEHO/Heading/H2/#.# Special tools @ 1\mod_1166540615553_31.doc @ 11465 @ 2

12.3 Special tools Pos: 50 /GEHO/Parts lists/Special tools/Project/814.201150.10=R02-2011-05-05 @ 11\mod_1295966090125_0.doc @ 80557 @

SET OF TOOLS


DRAWING NUMBER

REVISION DATE: R03=05.05.2011


001 897.010.685BD ACCUMUL.FILLING DEVICE 1

002 897.010.623G HYDR.ASS/DISASS D.H.COVE 1

003 897.050.338 PULLING DEVICE CYL.LINER 1

004 897.010.635 TOOL VALVE NUT 1

005 897.050.148 ASS.VALVE SEAT TOOL 1

006 897.010.728P DISASS.VALVE SEAT TOOL 1

007 897.010.710 HYDR.PUMP-UNIT 1

008 897.050.345 DISASS.TOOL GUIDE BUSH 1

009 897.010.679R LIFTING COVER 1

010 897.010.643M FIL.RING LIFTING COVER 1

011 897.010.689Q HOISTING UNIT 1

012 897.010.773 MANUAL CRANK UNIT 1


12.4 201150-IOM-EN-R03


201150-IOM-EN-R03 12.5

ACCUMUL.FILLING DEVICE DRAWING REVISION: 00

PART LIST NUMBER 897.010.685BD



001 973.900.028 ACCUMUL.FILL/CONTROL SET HYDAC 1

002 973.900.920 SAFETY VALVE 1

004 973.900.908 ADAPTOR 1

005 922.950.951 MANOMETER COUPLING MAV 6S/1/2"NPT-SS 1

006 921.510.325 PRESSURE GAUGE R63/0-16BAR 1


12.6 201150-IOM-EN-R03


201150-IOM-EN-R03 12.7

HYDR.ASS/DISASS D.H.COVE DRAWING REVISION: 00

PART LIST NUMBER 897.010.623G



001 897.101.040 TENSION RING 1.7225V 1

002 853.200.522 CLAMPING BUSH 1.7225V 24

003 862.050.127 NUT NF M48/D2510 24

004 933.100.083 SEALING RING R80-R95-12.5/T23 24

005 933.100.097 SEAL RING R95-R115-12.5/T18 24

006 914.300.047 EYE BOLT D580 M20 1.0401 1


008 960.010.621 ADAPTER R1/4"XR1/4"-3000B 1

011 960.010.624 BLIND PLUG 1

013 897.100.932 PIN 1


12.8 201150-IOM-EN-R03


201150-IOM-EN-R03 12.9

TOOL VALVE NUT DRAWING REVISION: 00




001 897.050.222 VALVE NUT WRENCH 1

002 897.100.823 PIN 3



005 897.100.824 PIPE 1


12.10 201150-IOM-EN-R03


201150-IOM-EN-R03 12.11

DISASS.VALVE SEAT TOOL DRAWING REVISION: 00

PART LIST NUMBER 897.010.728P



001 897.101.172 PULLER BLOCK 1

002 897.101.173 BLOC 1

003 897.101.174 THREADED ROD 1

004 853.200.503 CLAMPING PIN 1

005 853.200.494 CLAMPING BUSH 1

006 933.111.080 ROD SEAL S8-80 2


008 960.010.621 ADAPTER R1/4"XR1/4"-3000B 1



12.12 201150-IOM-EN-R03


201150-IOM-EN-R03 12.13

HYDR.PUMP-UNIT DRAWING REVISION: 00




001 960.010.036 HYDRAULIC PUMP HF-B225/0-2000BAR 1

002 960.010.623 ADAPTER 1/4"BSP/9/16"-18UN 1


004 928.900.130 HIGH PRESSURE HOSE 2500RED-5000 1


12.14 201150-IOM-EN-R03


201150-IOM-EN-R03 12.15

LIFTING COVER DRAWING REVISION: 00

PART LIST NUMBER 897.010.679R



001 897.050.281 LIFTING DEVICE 1


003 914.300.063 RING BOLT D580 M30 C15 1

004 897.100.948 DISC 1.7225V 1


12.16 201150-IOM-EN-R03


201150-IOM-EN-R03 12.17

FIL.RING LIFTING COVER DRAWING REVISION: 00

PART LIST NUMBER 897.010.643M



001 897.050.277 LIFTING DEVICE STL 1

002 897.100.808 T-NUT 1

003 914.300.047 EYE BOLT D580 M20 1.0401 1

004 862.005.319 BOULON 3

005 917.276.047 LOCK WASHER M20 D7349-ST-VERZ 1


007 897.100.819 PLUG 1

008 914.003.251 HEXAGON BOLT D931 M12X120 1

009 915.350.034 LIFTING EYE NUT M12 DIN582-C15 1


12.18 201150-IOM-EN-R03


201150-IOM-EN-R03 12.19

HOISTING UNIT DRAWING REVISION: 00




001 897.100.968 SUPPORT STL 2


003 897.101.150 HOISTING BEAM 2


005 914.106.688 HEXAGON BOLT D933 M42X90STL-GLV 24

006 897.101.221 TRANSPORT BEAM 2


010 897.050.374 HOISTING TOOL 2


12.20 201150-IOM-EN-R03


201150-IOM-EN-R03 12.21

MANUAL CRANK UNIT DRAWING REVISION: 00




001 980.622.915 SOCKET WRENCH 1

002 980.627.097 SOCKET 32/SL.W.36 1


Appendix: Electrical information

201150-IOM-EN-R03 13.1

Pos: 52 /GEHO/Heading/H1/#. Appendix: Electrical information @ 1\mod_1169571364915_31.doc @ 11974 @

13 Appendix: Electrical information Pos: 53 /GEHO/General/Attention, Warning and Note/DANGER - Safety - Obey safety instructions and procedures @ 0\mod_1136886637385_31.doc @ 1007 @

DANGER

• Obey the safety instructions.

• Obey the working procedures.

Pos: 54 /GEHO/Electrical information/Project/201150 @ 6\mod_1233221453885_31.doc @ 46334 @

Drawing number English document titles

S.814.201150.05 "LOGIC DIAGRAM"

S.814.201150.06 "CONTROL BOX AND TERMINAL BOX"

S.814.201150.07 "ELECTRICAL INSTALLATION"

S.814.201150.09 "MOTOR CONTROL CIRCUIT" Pos: 55 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765 @

Appendix: Catalogue information

201150-IOM-EN-R03 14.1

Pos: 56 /GEHO/Heading/H1/#. Appendix: Catalogue information @ 1\mod_1169571471475_31.doc @ 11978 @ 1

14 Appendix: Catalogue information Pos: 57 /GEHO/Catalogue information/General instructions, tightening @ 8\mod_1258016216015_0.doc @ 56511 @

General instructions REFER TO

General tightening procedure for flanges and gaskets A.807.005.119 A Pos: 58 /GEHO/Catalogue information/Project/201150=R03 @ 6\mod_1233130634577_0.doc @ 46169 @

GEHO TZPM 2000 assembly (820.587.201150) T.820.201150 REFER TO

PULS.DAMPENER FILLING UNIT (818.080.559AV) T.818.080.195 REFER TO

VALVE 921.020.062 A

LUBRICATION UNIT (828.950.126Q) T.828.900.362 REFER TO

ELECTRIC MOTOR 950.261.864 B

GEAR PUMP (L 960.020.073 C

SUCTION FILTER-ELEMENT 921.700.832 C

BALL VALVE 928.860.027 C

FILTER HOUSING 921.700.417 C

FILTER ELEMENT 921.700.836 C

FLOW SENSOR 971.600.008 C

DIAPHRAGM HOUSING UNIT (832.010.279D) T.832.000.214 REFER TO

NEEDLE VALVE 921.050.001 D

FRAME UNIT (845.010.456Q) T.845.000.459 REFER TO

GATE VALVE 921.150.071 E

OILGLASS 948.790.002 E

FILTER 921.700.033 E

BALL VALVE 921.200.026 E

PRESS.LIMIT.REGUL.UNIT (853.010.237K) T.853.000.233 REFER TO

SAFETY VALVE 921.300.583 F

NEEDLE VALVE 921.050.001 > D

PRESSURE TRANSMITTER UNIT (855.010.055AA) T.855.000.089 REFER TO

PRESSURE TRANSMITTER 971.450.059 G



Appendix: Catalogue information

14.2 201150-IOM-EN-R03

PROPELLING LIQUID UNIT (857.010.126Q) T.857.000.208 REFER TO

ELECTRIC MOTOR 950.261.864 > B

GEAR PUMP (R 960.020.063 H

FILTER HOUSING 921.700.411 H

FILTER ELEMENT 921.700.831 H

HYDR. ACCUMULATOR 973.000.012 H

3/2 WAY VALVE 972.200.065 H

3/2 WAY VALVE 972.200.066 H

3/2 BALL VALVE 928.860.019 H

FLOW SENSOR 971.600.008 > C

LEVEL INDICATOR 948.790.105 H

BALL VALVE 921.200.026 > E

SUCTION FILTER-ELEMENT 921.700.832 > C

AIR VESSEL UNIT (851.010.112F) T.851.000.392 REFER TO

PRESSURE TRANSMITTER 971.450.059 > G

ACCUMUL.FILLING DEVICE (897.010.685BD) T.897.000.374 REFER TO

ACCUMUL.FILL/CONTROL SET 973.900.028 I

SAFETY VALVE 973.900.920 I

HYDR.PUMP-UNIT (897.010.710) T.897.000.318 REFER TO

HYDRAULIC PUMP 960.010.036 J

DRIVE UNIT (814.201150.16) T.814.201150.16 REFER TO

ELECTRIC MOTOR 814.201150.30 K

GEAR BOX 814.201150.31 L

FLEX.COUPLING MOTOR-GEARBOX 814.201150.32 M

GEAR COUPLING CRANKSHAFT-GEARBOX 814.201150.33 N

FREQUENCY-CONVERTER 814.201150.38 O

TRANSFORMER 814.201150.39 P

ELECTRICAL UNIT (858.010.118N) T.814.201150.42 REFER TO

INITIATOR 971.100.055 Q

GEHO HMI TOUCH SCREEN: LINK CD 814.201150.37 R

PLC Technical Data: LINK CD + INTERNET PLC.S7-300-EN S

Weir Netherlands b.v.

P.O. Box 249, 5900 AE Venlo, the Netherlands

Egtenrayseweg 9, NL-5928 PH Venlo

4495

Registration No.: 12032525

Tel: +31(0)77 3895200

Fax: +31(0)77 3824844

Email: [email protected]

www.weir.nl

ExcellentEngineeringSolutions

TECHNICAL QUOTATION To : CBA – Cia Brasileira de Alumínio Alumínio, São Paulo Brazil Attention : Mr. Renato Moura Carlos Parisi Luiz Pozzi Cláudio Pavanelo Date : 01 February 2007 Project : Red Mud high concentration disposal system Proposal No. : 07EK0201 Record No. : i/s/br/CBA/07EK0214-QR0 Scope Description : System components and GEHO triplex single acting crankshaft drive piston

diaphragm pumps, model TZPM 2000

To: CBA Proposal No. 07EK0214-QR0

Revision 0 dated 14 February 2007

Page 2 of 18

Contents

1 Introduction 3

2 Engineering conditions 5

3 Scope of Work 6 3.1 Included in scope of work 6 3.2 Work to be included by Engineering and Construction Partners 8 3.3 Not included in Geho System Scope of work 9 3.4 Battery limits 9 3.5 Spare parts Consumption 9 3.6 Labour Requirements 9

4 Specific advantages of the proposed system 10

5 Pricing schedule 11

6 Commercial Notes 12

7 Technical Description GEHO piston diaphragm pump TZPM 2000 14 7.1 Work not included in pumps supply 18



Page 3 of 18

1 Introduction

Dear Mr. Moura, Parisi, Pozzi, Pavanelo As per our discussion we have the pleasure to quote to you attached for the supply of know how, engineering services and equipment to allow your contractor to complete the installation of a High Concentration Slurry Disposal system for red mud. The proposal is based on the concept to allow the contractor to install the system at the lowest possible costs. This is achieved through the supply by GEHO Pumps of the main components and of engineering and services of only the essential work, which requires GEHO’s specific support and technology. A local contractor will cover all other aspects with respect to completeness of the scope. Most alumina plants operate a HCSD system for red mud with a stand by capability installed for selected components including the main line GEHO pump. This quotation includes two (2) triplex single acting crankshaft drive piston diaphragm pumps, model TZPM 2000, of which one (1) will be in operation and one (1) will act as stand-by. In chapter 7, the scope of supply regarding these TZPM 2000 pumps is clearly defined. As an option we have also included a stand by agitated retention tank and related components, in case the existing system does not remain stand by. The system proposed provides for the red mud filter cake dumped in the Agitated Retention Tank to be conditioned to the correct rheological properties. This ensures the mud has the proper flowing behavior to spread out on the disposal site at an angle of repose, virtually without release of water. The correct behavior is primarily achieved through shear thinning and addition of water. A control loop continuously monitors the differential pressure and density of the slurry. If required the rheology of the slurry is altered automatically through the addition of water. We propose the ART be placed next to the strainers. Two centrifugal booster pumps (one (1) operating and one (1) stand by) feed the mud through the installed suction strainer. The strainer ensures that oversized material does not enter the mainline pump. The slurry is transferred to the mainline GEHO piston diaphragm pumps via atmospheric air vessels. The GEHO piston diaphragm pump model TZPM 2000 will develop the pressure required to transfer the mud to the end of the 21.4 km pipeline. After award GEHO Pumps will perform site rheological verification tests. We will be responsible for the (basic) design of the system and the control and operating philosophy through the supply of drawings and data sheets as per our quotation. Detailed engineering as well as actual construction work and supply of suction as well as discharge piping (16” pipeline, acc. GEHO basic engineering) is left to the local contractor. GEHO Pumps will actively support and advice your contractor during the project execution from the Netherlands: drawings will be reviewed and commented and the completed installation will be reviewed. GEHO pumps will assist in commissioning and start up of the components and system. The system will be designed for a life to exceed 30 years of operation. Spare parts costs will be low due to the use of the piston diaphragm pump, which makes use of a rubber diaphragm to protect the vital parts from the abrasive slurry. As a result only the mainline pump valves are subject to abrasion apart from the booster pump internals. The consistency of the mud contains no excess water (water and energy is saved) and is disposed with release of hardly any water. This normally eliminates the need for a recirculation system, further reducing operating costs. Rain water will run off the sloped deposit at a low velocity to limit any erosion and often may be released to the environment. The system in our estimation and depending on your schedule should be made operative after approximately 16 months from award and receipt of payment security.



Page 4 of 18

Yours faithfully, Weir Minerals Netherlands b.v. GEHO PUMPS Erik van der Kuy Erik Vlot Theo Tosserams

Area Sales Manager. Product Manager Systems Applications Engineer GEHO Pumps



Page 5 of 18

2 Engineering conditions

Description of plant: � Type : Alumina plant � capacity : 257 t/h Description of waste products:

Slurry quantity m3/h

Waste product min. Max.

Particle size distribution available yes/no Please attached

Sample available yes/no

Chemical composition available yes/no please attached

Red Mud 38 382 no yes no

Required technical conditions: � Length to furthest end on disposal area (m) : 21.4 km � Total static head (m) : -102 m � Drawing of disposal site available : yes Climatic conditions: � Installation : outdoor sheltered � Temperature ambient : min. 5°C, max. 45°C Make-up water: � Source : unknown � Chlorides content : nil � Sulphur content : nil � pH : unknown



Page 6 of 18

3 Scope of Work

3.1 Included in scope of work

The slurry preparation, transportation and disposal system incl. agitator, charge pumps and GEHO piston diaphragm pumps, according GEHO proprietary design criteria and specifications

Item Qty. Description

1 1 Agitated Retention Tank (ART) for optimisation of the slurry consistency and homogenisation, comprising of: � Tank, in fabricated steel, diameter approx. 5.6 m, height approx. 7.8 m. Basic design

(overall dimensions) by Geho Pumps. Local third party (contractor) to supply detail design and steel structure.

� High-torque agitator, make Hoesch, complete with gearbox and motor drive, specifically designed for this severe duty.

2 1 Slurry Control Unit (SCU) for the on-line monitoring of the slurry quality, comprising of: � Peristaltic pump complete with drive (GEHO supply). � Differential pressure measurement (GEHO supply). � Density measurement (GEHO supply). � Basic design for control loop (GEHO supply). � Control loop PLC (GEHO supply). � Control loop shut off and flush valves (GEHO supply) � Pipe loop piping and air over slurry pulsation damper by third party. � Slurry control unit to be mounted at the ART tank wall by third party. � All wiring to be third party.

3 1 Water dosing system: (GEHO supply) � Motor operated water valve, flow meter, pressure transmitter, pressure switch. � Water flow required is 175 m3/h, water pressure required between 5 – 7 bar, water supply

by third party. � Installation and wiring by third party.

4 2 Booster pump, centrifugal type: � With suction directly from the ART. � Pump in high-chrome, wear resistant execution for pump casing and impeller. � Specifically engineered for high viscous red mud slurry application. � Base frame. � E-motor. � V-belt transmission. � Counter flanges. � Gland water harness including flow switch. � Civil work, piping and wiring by third party.

5 1 Lobster pot: Basic design by GEHO Pumps, detailed design and manufacturing by third party.

6 2 In-line suction strainer



Page 7 of 18


7 2 Suction air vessel: � In main pump suction line � To provide a virtually momentum-free absorption of pressure pulsations � To protect booster pump from pressure surges � Including suction pressure transmitter � Including pressure gauge � Compressed air connection

8 2 � Main line pump: GEHO triplex single-acting crankshaft driven piston diaphragm pump

type TZPM 2000. For scope of supply, please refer to chapter 7 of this quotation.

9 1 Process control system (by third party) � Both mainline pump and slurry control unit have dedicated plc with graphic user interface. � Integration of (automated) process control to be executed by third party. � Signals can be made available in hardwire execution. Communication via ethernet is

optional.

10 1 Discharge pipeline (by third party) � Nominal 16 inch, 160 bar design, length ca. 21.4 km, by third party.

11 Lot Low pressure slurry valves (GEHO supply): � Manually operated � Isolation, booster pump suction � Flush water, booster pump suction � Drain, booster pump discharge � Isolation, booster pump discharge � Flush, lobster pot � Drain lobster pot � Flush, suction strainer � Drain suction strainer � Isolation, GEHO pump suction � Flush water, GEHO pump suction � ART drain valve

12 Lot High pressure valves (GEHO supply): � Manually operated � Drain, GEHO discharge � Isolation, GEHO discharge

13 1 Lot of commissioning spare parts (GEHO supply)

14 Lot General components and instrumentation (GEHO supply): � Level sensor for agitated retention tank � Slurry dilution valve in booster pump suction � Pressure transmitters discharge pipeline

15 1 Supervision during installation and commissioning by one GEHO service engineer.

16 1 Commissioning by one GEHO system engineer.



Page 8 of 18


17 1 Basic system engineering package The price allows for the basic system design of the preparation and transportation system. This basic design package will serve as input for the required detail design to be performed by a third party. The basic system design includes: � Design basis � Basic P&I drawing � Basic pump station layout. � Basic design lobster pot � Discharge pipeline diameter and wall thickness calculations. � Equipment list � Valve list � Drive list � Operation and control philosophy � Operating manual for slurry control unit � Laboratory testing of samples. A representative sample of 10 liters to be provided within 2

weeks after signing of contract. � Three design meetings in Brazil

18 1 Free annual installation performance review by GEHO Customer Care Department

3.2 Work to be included by Engineering and Construction Partners

� Engineering and detailed design � Mechanical � Electrical � Civil � Structural � Piping � Programming

� All hardware as partially indicated above. � Agitator retention tank (ART), including all connections, totally enclosed. � Mounting and assembling of all Slurry Control Unit components onto the ART. � Lobster pot. � Process control system, including required programming. � Discharge pipeline, including all accessories, routing, structural calculations, stress analysis. � All other components as per the requirements of the system.

� Pump station detail design. � All interconnecting piping and wiring.



Page 9 of 18

3.3 Not included in Geho System Scope of work

The Purchaser / Contractor will have to provide the following utilities, equipment and services: � Civil engineering and construction. � Installation labour. � Electrical hook-up of drives and control systems. � Initial filling of lubricants, gas, propelling liquid and so on. � Finish painting. � All interconnecting piping and wiring to and from units. � Feed line(s) from drum filters the agitated retention tank. � Approximately 175 m³/h make up water supply to the proposed water dosing system. � Approximately 380 m³/h flush water supply. � Air-conditioned control room for VFD and or System PLC control. � conditioned air at 500-700 kPa for operation of propellant inlet/outlet valves fitted to the diaphragm stroke

control system � external piping to the unit � anchor bolts supply � motor starters for main and auxiliary drivers � platforms, stairways and safety railing as may be required It is expected that the local contract partner will fill in all gaps between what is in the scope of supply of Geho Pumps and the requirements from the plant owner.

3.4 Battery limits

� Top of ART tank filter cake feed opening. � Mainline pump discharge flange. � Make up water dosing valve entrance. � Electrical power supply connections. � Electrical control connections outside control cabinet and pump.

3.5 Spare parts Consumption

A GEHO representative will assist the staff, which manages the pumps, to evaluate the usage and make arrangements to assure the availability of the spare parts. The manufacture of these parts concurrent with the pump will result in cost savings and a discounted price. Complete parts lists for all equipment and accessories supplied will be submitted within 3 months from the date of contract award.

3.6 Labour Requirements

Operating � Once the installation is properly installed and commissioned, it will run fully automatically and can be

controlled from the Central Control Room (CCR) or if so, to local control room. The proposed equipment therefor does NOT require any ADDITIONAL operating personnel.

Maintenance � The design of the installation is based on rigid and wear resisting components In combination with a very

easy and quick access of these wear components, the replacement of wear parts will require only a short interval, typically approximately 2 hours for 1 pump. Total maintenance required will not exceed approx. 250 hours annually, which results in an unequalled high pump availability of more than 98%!



Page 10 of 18

� Specific advantages of the proposed system

Since early eighties, it is possible to transport high-density slurries (practically without free water) through a long distance pipeline. It is subsequently possible to dispose (waste) slurry in an environmentally safe and sound way. These possibilities became economically viable through the development of high-pressure piston diaphragm pumps. Compared with the conventional ways of transportation by means of conveyor belts, trucks or low density slurry pumping, the proposed high-density transportation and disposal technology offers you following: Environmental advantages: � Minimal or no ground water pollution because of the solidification of the slurry on the disposal site. � Minimal or no dusting because of the solidification of the slurry. � Easy drainage of rainwater. � Hills can be easily constructed in order to recreate the original landscape. � Possibility of re-cultivation / re-vegetation. � The pipeline can be buried underground and remains invisible. � No topographic limitations to the pipeline systems. � No pollution during transportation because of fully enclosed pipeline system. � Disposing high-density tailings requires less volumetric space than low-density tailings.

Operational advantages: � The slurry preparation, transportation and disposal is completely automated. The entire system can be

operated and controlled at one location. This location can be the plant's Central Control Room. Thus no additional manpower is required.

� The slurry preparation, transportation and disposal is continuous and trouble free. � The system is not influenced by weather conditions etc. � No additional manpower or machinery is required to spread the waste over the whole area of the

disposal site. � Therefore no accommodations for personnel or equipment on the disposal site are required. � Flexibility: a later change of the pipeline routing is possible at low costs. � The pipeline system provides adequate standby facility and allows for more freedom of layout (routing). � The installation offers high availability and reliability in summer as well as in winter seasons. � The installation is maintenance friendly. � Easy cleaning possibilities of installation and pipeline. � Self-cleaning of pipeline because of positive displacement pump characteristics. Financial advantages: � The pump system is designed to operate 25 to 30 years, thus reducing the depreciation per year. � The energy consumption of a pump system is low due to low flow rate and high pump efficiency

(90…95%). � High operating costs (high spare parts consumption and labour) of trucks and belts are eliminated. � No energy consumers (infra structure!) on the disposal site. � Less volumetric space required for disposal lead to lower costs for disposal site preparation. � Low capital costs for lagoon & dam construction. � No costs for removal of scaling in pipeline. The above issues have been purposefully kept brief, but show that the proposed system is proven technology, ecological preferable and certainly reducing the total operating and investment costs.



Page 11 of 18

4 Pricing schedule

Slurry preparation, transportation and disposal system designed to be operated remotely from a control room, comprising of an agitated retention tank, charge pump and GEHO piston diaphragm pump.

Item Qty. Description Price in EURO

1 1 Agitated Retention Tank (ART) Included

2 1 Slurry Control Unit (SCU) Included

3 1 Water dosing system Included

4 2 Booster pump, centrifugal type Included

5 1 Lobster pot, basic design only Included

6 2 In-line suction strainer Included

7 2 Suction air vessel Included

8 2 Main GEHO TZPM triplex single acting crankshaft driven piston diaphragm pump type 2000

For scope of supply, please refer to chapter 8!

Included

9 1 Process control system Contractor

10 1 Discharge pipeline Contractor

11 Lot Low pressure slurry valves Included

12 Lot High pressure slurry valves Included

13 1 Lot of commissioning spares Included

14 Lot General components and instrumentation Included

15 1 Supervision during installation and commissioning Included

16 1 Commissioning by System engineer - 15 mandays on site with 10 hour working days. Should we be forced to exceed these number of mandays for reasons attributable to CBA or their contractor we will have to charge extra.

Included

17 1 Basic system engineering package Included

18 1 Free annual installation performance review Included

Total lump sum price EURO

4.1 Optional prices

Item Qty. Description Price in EURO

19 1 Stand-by Agitated Retention Tank (ART), including:

* Agitator



Page 12 of 18

Item Qty. Description Price in EURO * Booster pumps * Control loop * Water Dosing unit * Valves

5 Commercial Notes

This proposal is without prejudice and has been prepared and submitted only for the purpose of providing you with a general outline of a dense slurry disposal system and the tentative capital expenditure. It may serve as a basis for further discussion and the development of the Design Basis. General conditions All tenders and contracts for the performance of deliveries by Weir Netherlands b.v. are governed by the ORGALIME General Conditions for the supply of mechanical, electrical and associated electronic products (S2000) of August 2000. A print of these General Conditions will be made available upon request. The following terms are in addition to and continue from the General Conditions to this Quotation. Payment Terms The proposal prices are based on the following payment schedule: 20% Down payment by bank remittance against our order acknowledgement. 30% after completion of basic design as per document list, by payment against an Irrevocable confirmed

Letter of Credit in conformity with ICC Uniform Customs and Practice for Documentary Credits (UCP 500), 1995 Revision, Publication No. 500.

50% By payment at sight against shipping documents against an Irrevocable confirmed Letter of Credit in conformity with ICC Uniform Customs and Practice for Documentary Credits (UCP 500), 1995 Revision, Publication No. 500.

The LC shall be opened within 60 days after the date of the Purchase Order or the Letter of Intent with an instruction to proceed, by a First-Class Bank for the benefit of the seller and confirmed by ABN/AMRO Bank upon the authorization or request of the issuing bank. The LC shall not expire earlier than 2 months from the contractual time for delivery and shall allow a period of 21 days after the date of shipment for the presentation of those documents, which will be mutually agreed to. The LC shall allow partial shipment. All charges within the country of the Buyer are for the Buyers' account, whereas all charges outside the country of the Buyer are to be borne by Seller. Pricing The proposal prices would remain fixed and firm throughout the validity period and the execution of the contract provided dispatch from our works is accepted in accordance with the offered lead time. Validity This proposal will remain valid and open for acceptance for a period of 120 days from the date of our offer. Trade (Shipping) terms Our point of delivery is FOB North Sea Port and will be governed by the provisions of INCOTERMS 2000.



Page 13 of 18

Time for delivery The current lead time for the equipment delivery is 12-14 months dating from receipt of your official order enabling uninterrupted manufacturing to proceed. Seller reserves the right to adjust the proposal price in the event the trading price of base metal used in the production of the equipment surges. The time for delivery will not be subject to a liquidated damages clause. Inspection is a respected right of our customers. Inspection must not interfere with work in progress and must be mutually acceptable and arranged with prior notice. Guarantee Seller agrees to repair or replace any product Seller manufactured which is found by Seller to be defective in materials or workmanship, providing that notice of claim of defect is received by Seller within one (1) year from initial equipment start-up or eighteen (18) months after shipment by Seller, whichever occurs first. Sellers' guarantee is contingent upon the use of spares supplied by Seller. Seller shall not be liable under any circumstances to indemnify or compensate the Purchaser for any special, incidental or consequential damages. This guarantee shall not be construed to cover corrosion, erosion, abrasion or wear resulting from normal use of the pumping unit in the specified service. Confidentiality All information, documents, etc. contained in or related to this Proposal and all attachments hereto are proprietary and shall be treated as confidential by the recipient. Such information and documents shall not be divulged by recipient or its personnel to any third party, unless recipient has first received written permission. The information contained herein is not to be released or disclosed for any other use or purpose other than evaluation of this Proposal and any subsequent Purchase Order resulting from this Proposal.



Page 14 of 18

6 Technical Description GEHO piston diaphragm pump TZPM 2000

The work will include, but will not be limited, to the following items: Item No. Qty Unit Description

1 2 Ea. Pump(s) : GEHO model TZPM and size 2000, three-cylinder, single-acting, crankshaft driven piston diaphragm pump(s), featuring:

Power-end: � cast power-end frame with shaft seals and inspection covers to seal

against exterior contamination � piston rod stuffing box to prevent lube oil contamination and leakage � direct-driven crankshaft i.e. without drive shaft and gearing � forged alloy steel crankshaft supported on self-aligning roller bearings � heavy duty anti-friction bearings used throughout � crossheads with replaceable guides � crosshead extension/piston rods constructed in sections to enable

simple replacement of pistons � integral pressurised lube oil system with one 100% capacity pump

powered by a 0,75 kW motor and a single cartridge type filter and supplemented by an independent splash lubrication system

� a turning gear device for manually rotating the pump in an unloaded condition

� lock-out of the motor driver when the turning gear is engaged Water-end: � water-end segmented to permit removal and replacement of individual parts required for maintenance � self-actuated, spring-loaded cone type pump poppet (check) valves with elastomer valve ring and valve

seats of sufficient size and material to minimize wear and abrasion encountered in abrasive slurry service. The valve seating surfaces are conically shaped and soft-seated with both a metal to metal contact surface, and also a metal to elastic contact surface. The metal to metal contact absorbs the high pressure differential across the valve. The sealing ring projects past the cone and is subject to abrasive wear and fatique caused by slurry particles pushed or forced into the elastomer contact surface. Generally the ring, worn on one side, can be reversed and re-used

� the common size pump check valves are mounted individually and are readily accessible for maintenance

� the valve seats are full taper to enable oil-hydraulic release for ease of replacement � oil-hydraulic tensioning in one pass of the valve housing cover studs for ease and speed of valve

maintenance � pre-moulded, contoured and guided diaphragms to protect the pump moving parts against abrasive wear � diaphragm housings shaped to minimise stresses in the clamping rim area, which is cold rolled to prevent

stress risers � oil-hydraulic diaphragm housing cover studs tensioning in one pass to eliminate inaccuracies and

additional stress from conventional torque methods � coating of all critical, larger diameter studs to prevent fatique cracking due to corrosion in the presence of

moisture; in particular the diaphragm housing cover and the valve housing cover studs � clamped liner for easy replacement � the piston slides in a precision-machined cylinder liner which is coated with 0.2 mm hard chrome plating

to provide a longer wear life and less frequent replacement � the cup seal is a proprietary design which is suitable for high operating pressures and provides a long

wear life



Page 15 of 18

� the Teflon-impregnated guide ring prevents the piston body from rubbing the cylinder � suction stroke sealing is accomplished by utilizing a standard lip seal � the piston design reduces friction between the piston and cylinder wall which allows for more efficient

operation � cylinder flushing to minimise wear and to provide coolant � ample size pump suction manifold terminating in a single ANSI B16.5 flange connection � ample size pump discharge manifold with ANSI B16.5 flange � one (1) suction airvessel to provide a virtually momentum-free absorption of pressure pulsations due to

flow fluctuation through the compression of air � two (2) GEHO nitrogen precharged discharge pulsation dampener(s) free draining and with renewable

bladder to reduce the pressure variation at the manifold outlet for both flow and acceleration induced pressure disturbances through the compression of nitrogen gas. Actual dampening depends on factors like precharge pressure and line discharge pressure

� nitrogen charging valve(s) � the pulsation dampener(s) will be designed and manufactured in accordance with the requirement of

ASME Section VIII Div. I 1988. The completed unit(s) will be registered with and stamped in accordance with the requirements of Lloyd’s Inspection Service or the equivalent

� An internal pressure relief system with one spring-loaded, self-seating relief valve (common to all diaphragm chambers) installed on the propellant liquid side of each diaphragm, which is fitted with proprietary non-return valves to protect each diaphragm chamber individually from over-pressurisation

Instruments and controls: � diaphragm stroke control with automatic adjustment of fill/drain valve actuation and opening time as

applicable � modular propelling fluid supply system minimizing the components mounted to the pump frame and for

accessibility and ease of maintenance � propelling fluid supply system with integral sump, one intermittently operating pump powered by a 0.75

kW motor and auxiliaries � proprietary design initiators � GEHO design, electrically actuated and pneumatically operated propelling fluid fill and drain valves to

provide a compact assembly and a quick response time � instrument wiring to a single terminal box � Siemens PLC with program scan time less than 20 milliseconds � the GEHO piston diaphragm pump is equipped with a control panel IP55 enclosure which monitors and

controls proper operation of the pump functions (mounting adjacent to the pump for operator convenience)

� the control system will conduct and monitor the pump starting, operating and shutdown sequences including all pump auxiliaries

� potential free contacts to motor control centers in the field and information of pump status to DCS system � flow switch to ensure proper operation of the lubrication system � automatic shutdown or alarm (at customer’s option) upon diaphragm rupture � automatic alarm upon overpressure in the discharge dampener gas side � automatic shutdown upon overpressure � the alarm, trip and relief valve set pressures standard are 5, 10 and 15% over the rated pump discharge

pressure Interactive, GEHOgraphics touch panel with high intensity monochrome display, providing: � Touch-sensitive screen for easy operator commands � visualisation of pump functions � read-out of variables � manual override of on-board control elements � alarm and event record display



Page 16 of 18

Optionally available: � Upon your request the pump control system may be expanded with communication hardware to the

customer DCS system (communication set up by customer) Shipping preparation: � shop coating all exterior ferrous metal surfaces to prevent oxidation � assembly to the extent possible as allowed by shipping limitations or for protection of components � protection against the entrance of moisture and dust � coating all non-painted surfaces with a rust inhibitor compound � a three-layer 140-220 micron Sigma coatings’ paint system with Polyamide cured epoxy primer and

acrylic-Polyurethane finish paint in Blue colour – RAL 5005 Materials of construction: Power end: � frame: nodular cast iron � crankshaft: forged steel � crosshead extension/piston rod: AISI 4140 plasma nitrated Liquid end: � cylinder liner: hard chrome plated steel � diaphragm housing: forged steel � valve housing: forged steel � dampener: forged steel Item No. Qty Unit Description 2 2 Ea. Pump gear drive system , comprising:

� one (1) Flender or equal, double engagement, crowned gear coupling, oil filled and mounted between

gearbox and pump � one (1) Flender or equal helical gear reducer � one (1) Flender or equal flexible coupling with accessible flexible elements and mounted between motor

and gearbox � coupling guards � structural steel base plate with horizontal positioning screws and jack bolts � pre-assembly � one gear reducer internal (submerged) lube oil cooler � one WEG or equal variable speed AC, medium voltage, motor driver, IP55 enclosure, with speed

adjustment range, class F insulation and rated for the absorbed power at the overpressure alarm within the class B temperature rise utilisation

� one WEG or equal variable frequency converter � one WEG or equal dry type reduced voltage transformer � painting of all drive components in accordance with manufactures standard procedure and standard color � testing in accordance with manufacturers standard tests



Page 17 of 18

Item No. Qty Unit Description

3 1 Set Special tools required for the normal maintenance of the pump(s), comprising:

� cylinder liner removal kit � valve seat mounting tool � valve seat removal tool � (cone) valve nut wrench � (cone) valve spring collet � diaphragm housing cover swivel bracket � air-driven hydraulic pump � nitrogen charge device � hydraulic diaphragm housing stud tensioner

Item No.

Qty Unit Description

4 1 Lot Submittal of drawings and data in English language and according to the time periods shown in the following table:

Within 8 weeks after receipt of purchase award the following drawings will be furnished for review: � drawing index � document submittal schedule � production schedule � inspection and test plan � pump torque-speed curve � dimensional outline drawing � foundation drawing � flushing requirements � piping and instrument diagram � instrument list � logic diagram � electrical schematics � wiring and connection diagrams � pump control panel lay-out � performance test procedure A progress report will be submitted bi-monthly Within 4 weeks after shipment the following will be furnished � manufacturing databook � installation, operations, and maintenance manuals (including those from sub-suppliers) on CD-rom Electronic data and drawings will be submitted in the following formats: � drawings: dxf-files � text: PDF-Format � spreadsheets: PDF-Format



Page 18 of 18

Item No. Qty Unit Description 5 1 Lot Quality assurance and quality control , comprising:

� implementation of a Quality Management System, which meets the requirements of ISO 9001 and has

been surveyed and approved by Lloyd’s Register Quality Assurance � certification, inspection and testing in accordance with an Inspection and Test Plan (ITP), which has been

proven adequate by successful manufacture and operation of similar pumps � submittal of a Manufacturing Data Book Item No. Qty Unit Description 6 2 Ea. Factory acceptance test , comprising:

� complete check out and adjustment of instrumentation and the control system � pressureless run-in � functional test of the PLC software � observation of mechanical performance and demonstration of alarm and trip signals � verification of hydraulic performance and rating values on water in accordance with the Hydraulic

Institute/ANSI Standard: ANSI/HI6.6-1994 with type II test acceptance values � post-test inspection to confirm the good operation of pump components � a report of the data obtained and calculations made as result of the test

6.1 Work not included in pumps supply

The Purchaser will provide the following utilities, equipment and services: � supply of nitrogen to pre-charge pulsation dampener/accumulator bladders. The nitrogen filled cylinder

shall be complete with pressure regulating valve and flexible charging hose � conditioned air at 500-700 kPa for operation of propellant inlet/outlet valves fitted to the diaphragm stroke

control system � water supply at 300-400 kPa for cleaning or flushing of the pump. The water (intermittent) capacity shall

equal or exceed 10% of the pump rated capacity � first charge and change of lubricants and propelling liquid � flushing water piping terminating immediately downstream the suction isolation valve and upstream the

discharge isolation valve � external piping to the unit � anchor bolts supply � electrical cabling and installations off-machine � motor starters for main and auxiliary drivers � platforms, stairways and safety railing as may be required

Key features of the GEHO crankshaft driven piston diaphragm slurry pump

Key features of the GEHO crankshaft driven piston diaphragm slurry pump

Nitrogen (pre)charged dampener(s)

reduces the residual pressure variation

to the specified level.

Choice of materials and

linings for corrosive and

abrasive slurries.

The poppet valves are the only wear parts. Various valve

designs and wear/corrosion resistant materials ensure a

most economical mean time between replacements.

Oil-hydraulic valve

seat removal.

Genuine, contoured and rod-

guided diaphragm selected from

a range of eight sizes, based on

empiric duty related data allows

for routine annual replacement.

Resilient, robust cast

frame, shaped for low

stress throughout.

Replaceable

cross-head guides

Conservative rod

load rating.

Guided low velocity

piston running in clean

propelling liquid.

Single over-pressure

relief valve protects all

diaphragm chambers.

Sealed against exterior

contamination.

Typical 98% availability,

up to 96% efficiency.

Forged alloy-steel crank-

shaft driven from external

gear reducer.

Pre-loaded, long-life roller

bearings enable rated

pressure at low speed.

Integral forced-feed

lubrication.

Diaphragm position

is controlled in either

direction by an integral

PLC controlled system

adding or removing

propelling liquid.

Supervisory control

panel PLC for all logic,

sequencing and alarm

raising functions.

Interactive touch

panel for operator

convenience.

SPEED

Operating pressure

High

START

/STOP

RESET

Too low

M1

OFF ANALOG

VALUES

VDF ready to runPump ready to run

Running hours

Number of strokes

: 0

: 0

97KPa(A)

97KPa(B)

LOCAL

REMOTE

Oil-hydraulic stud

tensioning enables

rapid valve replace-

ment.

High-pressure

diaphragm housing

minimizes stress in

clamping rim area.

Oil-hydraulic stud

tensioning eliminates

inaccuracies and

stress from torquing.

Weir Minerals Netherlands b.v.

Tel: +31 (0)77 389 52 00

Fax: +31 (0)77 382 48 44

Email: [email protected]

www.weirminerals.com

Copyright © Weir Minerals Netherlands b.v. 2006

P.O. Box 249, 5900 AE Venlo, the Netherlands

Egtenrayseweg 9, NL-5928 PH Venlo

4495

Registration No.: 12032525

Complete range single and double-acting pumps (shown above), modular design with wide variety of matching units.

Documents

Manual de instalação, operação e manutenção Installation ... · This manual with its user and safety instructions is an integral part of the pump delivery and must be kept in