Metso Orion Series Manual

Operation & Maintenance Manual
The Orion Series of Horizontal Slurry Pumps
MM200 EHC-D
Pump No
25411801001/A5684, 25411801002/A5685
Supplier / Order Nr
Metso Minerals (UK) Ltd. / 110546
Customer Name
Pigott Shaft Drilling Ltd.
2005-11-11 ed 2005-12-13

Slurry Pump
WH02AAAAAA0EN_03B.DOC JAN 04-W08 Content 1/2
1. GENERAL
1.1 About this manual
1.2 Transport and storage
1.3 Pump specification
1.4 Customer service
2. DESCRIPTION
2.1 Product and warning signs
2.2 Applications
2.3 Design
2.4 Materials and maximum working pressures
2.5 Surface treatment
2.6 General arrangement
2.7 Performance curves
2.8 Certificates & test results
3. HEALTH & SAFETY
4. DESCRIPTION OF OPERATION
5. CONTROL SYSTEM
6. INSTALLATION
6.1 General
6.2 Foundation requirements
6.3 Installation tools and equipment
6.4 Installation procedure
6.5 Pipe connections & pump sump
6.6 Shaft gland
6.7 Motor and operation
7. COMMISSIONING

Slurry Pump
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8. OPERATING INSTRUCTIONS
8.1 Starting
8.2 Stopping
8.3 Running checks
9. CARE AND MAINTENANCE
9.1 Safety measures
9.2 Preventive maintenance & service schedule
9.3 Tools and special equipment for service and maintenance
9.4 Lubrication instructions
9.5 Dismantling and assembly
9.5.1 Setting pump clearances
9.5.2 Hydraulic parts and frame - removal and fitting
9.5.3 Shaft seal – removal and refitting
9.5.4 Shaft and bearing assembly - removal and fitting
9.5.5 Shaft and bearings - disassembly and re-assembly
9.5.6 Pump drive - dismantling and reassembling
9.6 Fault tracing schedule
10. SPARE PARTS
10.1 Recommended stock of spares
10.2 Storage of spare parts
10.3 Spare parts ordering procedure
10.4 Spare parts drawing
10.5 Parts list
10.6 Special tools
11. APPENDICES
11.1 Torque table
11.2 Reference publications list
11.3 Weights table

Slurry Pump
WH03AA1AAA0en_03b.doc JAN 04-W08 General 1/6
1 GENERAL
1.1 About this manual
This manual is a part of the equipment to which it relates. It is written for the use of
installers, commissioning engineers, operators and maintainers. It should be kept for the
life of the equipment and, in case of re-sale, passed on to any subsequent purchaser.
Information contained in this manual is specific to the equipment and is correct at the date
of publication. As improvements are continually being made, Metso Minerals reserve the
right to make alterations to the equipment design and specification without giving prior
notice. Any amendments issued by Metso Minerals should be promptly inserted into this
manual.
© 2004 — Metso Minerals (Sala) AB. The contents of this manual must not be
reproduced without the prior written permission of Metso Minerals (Sala) AB.
1.2 Transport and storage
1.2.1 Delivery
A pump is either dispatched as an individual unit (bare shaft pump) or mounted complete
with drive unit on a bedplate (pump-set). In either case, any exposed machined parts are
coated with a suitable rust inhibitor.
Each pump is supplied complete with inlet and outlet flanges and gaskets, drive key, and
with the bearing cylinder charged with grease.
The packing or boxing will always be more than adequate for the method of shipment and
subsequent storage.
On receipt of the pump, check that the items listed on the consignment list have been
supplied and have not been damaged in transit. Ensure that the inlet and outlet apertures
are clear and that the impeller runs freely when the shaft is turned by hand.
If the pump has been disassembled for shipment, a consignment list will contain complete
information on the identification of parts. Where parts are boxed, each box is numbered
and the corresponding number is noted on the consignment list.
If damage has occurred or any items are missing, immediately file a report with the carrier
making the delivery. Also, submit a written report to Metso Minerals detailing the damage
and/or missing items, as soon as possible.

Slurry Pump
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1.2.2 Handling and lifting
Whether at the depot or on site, ALWAYS follow normal handling and lifting procedures and
instructions contained or referred to in this manual.
Handling of centrifugal pumps requires great care, especially larger or more cumbersome
items of machinery. All slinging, lifting or conveying MUST be carried out by appropriately
skilled personnel.
Always lift slowly and smoothly, maintaining the pump in a level attitude.
For your covenience and safety, approximate weight of the pump, or pump complete with
drive unit and baseplate, is in the Appendices, Section 11.
WARNINGS
MAKE SURE THAT ALL SLINGS, SHACKLES, ETC. USED ARE OF ADEQUATE LOAD CARRYING CAPACITY
FOR THE UNIT TO BE LIFTED. CHECK THAT ALL LIFTING EQUIPMENT CERTIFICATES ARE CURRENT.

Slurry Pump
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1.2.3 General storage instructions
• Re-apply rust inhibitor to all moving parts, at least, every two months.
Protect pump against dust and weather by storage indoors or under weatherproof cover
Protect pump against impact Turn shaft at least every month

Slurry Pump
WH03AA1AAA0en_03b.doc JAN 04-W08 General 4/6
1.2.4 Long-term field storage
Minimum requirement for storage and maintenance of centrifugal type pumps on site
before their installation and start-up.
1. Medium term storage
Indoor storage of equipment is recommended in order to prevent the harmful effects of
exposed conditions, particularly in dust laden atmospheres.
The standard anti-rust protection provided prior to dispatch remains adequate for periods
not exceeding two months.
Whenever indoor storage is not possible, it is necessary to follow the guidelines given
below:
a) Locate the pump set with its bedplate on a concrete floor and supported on
wooden joists of approximately 100 mm x 100 mm in section.
b) Cover the pump set, whether located indoors or outdoors, with a strong,
waterproof cover extending down to the baseplate. The cover must be securely
fixed to withstand ambient weather conditions.
c) Prior to fitment of the cover, ensure that:-
i. all openings, including inlet and outlet apertures, are properly sealed, and;
ii. the bearing cylinder and drive are properly protected against dust.
2. Prolonged storage -up to 2 years
The following steps are essential in all cases where prolonged storage is foreseen:
a) The pumps are to be adequately warehoused in a closed dry and, if possible, a
temperature controlled building.
b) Every six months, the stuffing box/shaft seal sleeve area should be inspected,
cleaned and re-coated with a suitable anti-rust compound, if required.
c) If disassembly of the pump is not practical then proceed as follows:-
i. Desiccate the pump case with hot air at 35°C to 65°C.
ii. Seal all pump openings and attach sachets of hygroscopic salts (silica gel).
iii. During the desiccation with hot air, ensure that no other parts become
overheated as this may be detrimental.
d) The pump rotor should be turned over several times by hand at intervals not
exceeding one month.
e) The bearing grease should be checked at least once every twelve months.
f) The bearing cylinder must be disassembled, cleaned and regreased prior to
reassembly at least once every 24 months.

Slurry Pump
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During prolonged storage, it may prove difficult to rotate the pump rotor manually for
normal maintenance. In such cases proceed as follows:-
a) Loosen the bearing end covers which limit the axial displacement of the
bearings.
b) Move the pump rotor along its axis, thus freeing the assembly and allowing
manual rotation.
3. Storage in excess of two years
For prolonged storage in excess of two years in adverse ambient conditions, special
protection may be necessary. Any moisture absorbing devices used must be absolutely
effective and regularly maintained. Whenever possible for storage periods in excess of two
years, it is recommended that all pump components are disassembled, washed, dried,
protected and reassembled afterwards. This work may be done by Metso Minerals and
charged to the purchaser under normal rates in force at the time the service is carried out.
1.2.5 Storage of spares
In general, unless otherwise instructed, keep all spares parts in a cool, dry environment
and protect rubberised/synthetic components from sunlight and high voltage electrical
equipment.
Rubber is affected by ageing and its rate of deterioration is dependent on the type of
rubber and the storage conditions. Rubber perishes most rapidly when exposed to heat,
ultra violet light and oxidants. The more commonly overlooked sources of which are
sunlight and electrical machinery. Rubber can become permanently deformed if
compressed out of shape during storage. Mineral oils, solvents, dust, contact with metals
and moisture can also damage rubbers depending on type.
Certain types of rubber such as chloroprene rubber (CR) harden at temperatures below
+5°C. In conditions of extreme cold these types of rubber harden to such an extent that
they could develop cracks and be damaged by handling. Chloroprene rubber does not
regain its normal hardness when the ambient temperature rises but has to be
reconditioned.

Slurry Pump
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To ensure rubber products maintain their original properties, storage conditions must be
controlled. Where practicable, ensure rubber products are:
1. kept sealed in their original packing which should be opaque;
2. kept away from direct sunlight;
3. kept away from electrical machinery -e.g. motors and generators;
4. kept in a cool, dry environment between 15° C to 25° C;
5. stored away from exhaust fumes;
6. stored separately from chemicals and fuels;
7. stored loosely packed;
8. rotated on a first in - first out basis.
Storage life for different types of rubber stored under recommended conditions are as
indicated in Table 1.2.5-1.
NOTE: AT 15°C THE STORAGE LIFE WILL BE ABOUT DOUBLE AND AT 35 °C ABOUT HALF OF THAT
STATED IN THE TABLE.
Type of rubber Product ref. Storage life @ 25°C (years) *
Natural NR 5
Nitrile NBR 7
Chloroprene CR 7
Butyl IIR 7
Ethylene-propylene EPDM 10
Chlorosulphonated polyethylene
(Hypalon) CSM 10
Table 1.2.5-1 Types of rubber and their expected storage life.

Pump MM200 EHC-D C5
Pump specification
Headline Description Qty
Machine sign showing A5684 and A5685
Order part no: 25411801000
Complete pump: PDW35141201
Pump type: MM200 EHC-D C5 2
Product code: 2261
Pump no: 25411801001 - 002
Frame size: FR400
Wear parts, quality: Chrome Iron
Special design: DISCHARGE POS 2 (HORIZONTAL UNDERHAND)
DRIVE SHAFT TURNED DOWN TO 60 MM (DRG CH4270)
BRG CART PT NUMBER PDWB05102. EXPELLER RING H/C WITH
GREASE NIPPLE. 150 TO 200 MM FLANGE ADAPTOR(500311-1)
Painting: MP15
Capacity m³/h:
Total head m:
Pump speed rpm:
Specific gravity kg/l:
Input power kW:
Motor:
Special req.:
Motor supplied by: Customer
Drive supplied by: Customer
Motor sheave:
Motor bushing:
Pump sheave:
Pump bushing:
V-belts:
Instruction: 1 in EN with the pump, PDF to J.Perry
25411801000 Edition 1 JAN 05-W46 General 1/1

Slurry Pump
WH05AAAAAUKEN_03C.DOC JAN 04-W08 General 1/1
1.4 Customer service
For any inquiry regarding the servicing and repair of Metso Minerals Slurry pumps please
contact the local Metso Minerals Branch. For information on the Metso Minerals Branch
closest to you, contact one of the Metso Minerals Global Sites listed below:
Metso Minerals (Sala) AB
Norrängsgatan 2
Box 302
S-73325 SALA Tel: [phone]
Sweden Fax: [phone]
Metso Minerals Industries, Inc.
P O Box 340
COLORADO SPRINGS CO 80901
621, South Sierra Madre (80903) Tel: [phone]
USA Fax: [phone]
Metso Minerals (UK) Limited
Parkfield Road
Rugby
CV21 1QJ Tel: [phone]
United Kingdom Fax: [phone]
Please provide the following information:
1. model and size of equipment;
2. serial number;
3. approximate date of purchase;
4. details of enquiry, apparent fault etc..

Slurry Pump
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2 DESCRIPTION
2.1 Product and warning signs
2.1.1 Product signs
All product signs attached to the pump are shown below.
Figure 2.1.1-1 Weight plate
The weight sign is mounted next to the machine sign. When the pump is supplied without
motor and drive, only the weight of the pump is stamped on the sign. In which case the
total weight is stamped on the sign by the mechanic who fits the motor and drive on the
pump.
Pump delivered without motor Pump delivered with motor
Space for CE-mark
Pump type
Pump number
Year of manufacture
Figure 2.1.1-2 Machine plate
A machine sign containing information as above is affixed to the pump.
A pump delivered with motor has a machine sign with CE-mark. When the pump is
delivered without motor the CE-mark has to be affixed when the motor is assembled.
The CE-mark is included in the pump delivery.
Motor weight
Drive weight
Pump weight
Total weight

Slurry Pump
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2.1.2 Warning and caution signs
This sign, attached to the drive cover, indicates the
direction of rotation of the pump when viewed from the
drive end.
THERE IS RISK OF SERIOUS DAMAGE TO THE PUMP IF IT IS
ALLOWED TO ROTATE IN THE WRONG DIRECTION.
This sign is a hazard warning and is usually
accompanied by text indicating the nature of the hazard.
THERE IS RISK OF SERIOUS INJURY IF THESE WARNING
INSTRUCTIONS ARE NOT OBSERVED.
The V-belt guard must always
be mounted during operation
WARNING
The sign is mounted on the V-belt guard.
The guard should always be
fitted when the pump is in
operation.
If the guard is to be removed,
check that the motor is
disconnected from the mains
or that the main switch is
turned off and locked so that
the motor cannot be started
inadvertently.
The guard must always be
refitted before the pump is
started.
This sign is attached to a direct-drive coupling guard.
Direction of rotation of the pump is indicated by this sign
attached to the front of the case.
This sign, attached to the frame, indicates that the pump
requires periodic greasing.

Slurry Pump
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2.2 Applications
The Metso Minerals Slurry Pump has been designed for a wide variety of abrasive
pumping duties. While the pumps may be used in many different industries, they are all
designed for constant use in the most arduous conditions. These high-efficiency pumps
are of a simple design, providing ease of maintenance and facilitating replacement of
wearing parts.
2.3 Design
2.3.1 General
Slurry Pumps are made up of four basic modules, the frame (A), the bearing cylinder (B),
the shaft seal (C) and the wet-end (D) assemblies – see Figure 2.3.1-1.
A comprehensive range of modules are available, to configure pumps to suit a wide range
of applications.
Pumps are supplied bareshaft or as fixed-base pumpsets with various choices of motor
mounting position. Manual or hydraulic slide-bases are optional.
Maximum efficiency is maintained by setting impeller running clearance(s). The adjustment
is easily carried out during maintenance and shut-down periods.
Standard bearing cylinders are grease lubricated, but oil lubricated bearings are an option.
Pump designation is made up of letters which identify the range and numbers which
indicate the inlet diameter in millimetres –e.g. HM150.
A
B
CD
Figure 2.3.1-1 Typical outline design of Metso Minerals Slurry Pumps showing the basic
pump modules: Frame (A), Bearing cylinder(B), Shaft seal(C), Wet-end (D)

Slurry Pump
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2.3.2 Noise level
In certain installations and outside the optimum operating conditions, the noise level of 70
dB(A) may be exceeded. The motor generates most of the noise and, in general, the
noise level for properly designed installations will be about 2dB(A) above that of the motor.
2.3.3 Vibration
The pumps are in ClassIV as described in ISO10816-1.
When the pump is new, the vibration level at any bearing should not exceed 7.1 mm/s.
Vibration levels above 11 mm/s should always receive attention.
CAUTION
SHOULD VIBRATION LEVELS EXCEED 18 mm/s, STOP THE PUMP IMMEDIATELY.
Common reasons for high vibrations are:
⇒ inadequately tightened fasteners;
⇒ slack V-belt;
⇒ misalignment of the drive;
⇒ the pump impeller is blocked by debris.

Slurry Pump
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2.4 Materials and maximum working pressures
Metso Minerals Slurry Pumps are constructed from materials selected to give excellent
wear characteristics over the full range of pumping duties. This section lists the materials
of construction and working pressures for STANDARD duty applications.
Other materials are also used for specialist applications or as specified by the customer
– see section 1.3 .
MATERIALS OF CONSTRUCTION
Item Material Type Material Code Material Standard
Case White Cast Iron JN3049 EN 12513
Impeller White Cast Iron JN3049 EN 12513
Back Liner White Cast Iron JN3049 EN 12513
Bearing Frame Cast Iron JS1030 EN 1563
Expeller White Cast Iron JN3049 EN 12513
Expeller Ring White Cast Iron JN3049 EN 12513
Expeller Ring (option) Cast Iron JS1030 PU Lined EN 1563
Stuffing Box Cast Iron JS1030 EN 1563
Shaft Sleeve White Cast Iron JN3049 EN 12513
Shaft Sleeve (option) Stainless Steel 1.4401 EN 10088
Shaft Sleeve (option) Stainless Steel 1.4021 EN 10088
Shaft Sleeve (option) Stainless Steel 1.4462 EN 10088
Shaft Steel 1.1191 EN 10083
Seals Nitrile Rubber NBR -
PUMP WORKING PRESSURES
SIZE Bar kPa
MM100 to MM400 15.0 1500

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2.5 Surface treatment
2.5.1 Standard finish
The external surfaces of the pump are protected by the anti-corrosive system specified in
Table 2.5.1-1, except exposed machined surfaces which are coated with an air drying rust
inhibitor. Drive motors are supplied in the original manufacturer’s standard finish.
Stainless steel, plastic or elastomeric parts are not painted.
Table 2.5.1-1 Paint specification
COATING TYPE COLOUR Finish 70 DFT (µm)
Finish
(all except
guards)
Two-pack gloss
oxiranester thick coat
paint
Blue
(RAL 5009) Gloss 120
Finish
(guards only) Epoxy powder Yellow (RAL 1032) Gloss 100
2.5.2 Paint repairs
To repair damage to a painted surface;
1. remove any trace of oil and dirt using solvent wash;
2. remove all loose paint by chipping or scraping back until only sound paintwork
remains and clean the exposed surface by wire brushing or other mechanical means
to grade St2 of Swedish Standard SS 055900 (ISO 8501-1:1988);
3. sand down and feather a 25mm band of the sound bordering paintwork;
4. vacuum the surface to remove all dust and debris;
5. apply the paint system specified in Table 2.5.1-1.

25411801000

25411801000

Pump MM200 C5
Performance curve
35AAAAHCHCC5 Edition 5 HWT 02-W35 Description 1/1
Full impeller dia
400 mm
Vane diameter
400 mm
Vane config
Full
Impeller type
Closed
No. of vanes
5
Max sphere
35 mm
Impeller material
Metal
Liner material
Metal
H (m)
200 400 600 800 1000
20
40
60
80
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800 r/min
BEL
60% 70% 75%
75%
78%
78%
80%
80%
70%
4,00 m
6,00 m
8,00 m
10,00 m
P (kW)
Q (m³/h)
200 400 600 800 1000
25
50
75
100
125
150
175 Based on clear water tests
correct for other conditions
700 800 900 1000
1100
1200
1300
1400
1500
1600
1700
1800