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Weir Minerals Division

Excellent Minerals Solutions

Weir Minerals México

MINERA ROBLE, S.A. DE C.V. Unidad Velardena Bomba Hazleton 75- 350 SHW pump No. Pedido: PO724.0000229317 Serial No: N- 27685

Built to Last

The design process of the Warman SHW madeextensive use of finite element stress analysis andstate of the art solids modeling to ensure rugged,dependable solids handling capability at the lowestpossible cost.

A heavy duty all chrome wet end coupled with a motor designed and built by Weir Minerals forthe most demanding applications makes theWarman SHW the most dependable, long lastingsubmersible pump you can buy.

The Warman SHW offers exceptional wear life and reliability, providing the lowest cost of ownership.

WARMAN®

Centrifugal Slurry PumpsSlurryEquipmentSolutions

SHW

SHW Design Features

• Temperature sensor – Over-temperature sensorsprotect the motor by sounding an alarm or shuttingdown the unit if internal temperatures exceed safeoperating limits.

• Moisture detector – A twin electrode system provides double protection by detecting moistureintrusion in either the motor housing or themechanical seal chamber.

• Mechanical seals – The SHW incorporatesWarman’s proven balanced double-seal arrangement in which both sets of seal springs are enclosed in the oil reservoir. Silicon Carbide Seal faces are subject to submergence pressure only for greatly extended wear life.

• Heavy-duty water end – Standard high chromeiron construction coupled with heavy section thickness provides the ultimate in protection against abrasive wear in heavy slurries.

• Easy maintenance access – T-bolt constructionallows rapid disassembly of the pump end for maintenance access. The heavy-duty impeller is not screwed on, but keyed to the shaft for easyremoval and protection against movement during reverse rotation.

• Optional agitator – A robust agitator can be fittedto the suction eye allowing the pump to agitatehigh concentrations of solids.

The Warman SHW has a unique combinationof features not found in any other submersible slurry pump.

advanced cable entry

temperature sensor

heavy duty thrust bearings

moisture detector

mechanical seals

heavy duty water end

easy maintenance access

Agitator design option B

Agitator Options

Two different agitator options are offered dependingupon solids type.

Agitator design option A allows a more completeremoval of fine solids. Agitator design option Baggressively agitates larger solids from the sump floor.Agitator design option A

Applications

• Mine dewatering

• Red mud recovery

• Clarifier sludge

• Coke quench

• Mill scale

• Seawater/sand slurry

• Clean-up sumps

• Lime slurry

• Skimming pit

• Coal pile runoff

• Kaolin clay

• Thickener drain

• Fly ash sump

• Bottom ash overflow

• Pond water return

• Black liquor

• Red mud decanting

• Boiler blowdown

• Magnetite recovery

• Coal fines recovery

• Precipitator slurry

• Chlorinated thickener

Part Material Specification

Casing A05 Chrome ASTM A532, Class III, Type AImpeller A05 Chrome ASTM A532, Class III, Type AImpeller nut 450 HT ASTM A564, HardenedShaft 416 SS ASTM A582, Type 416Fasteners 316 SS ASTM A193, Grade 8BMMotor housing Cast Iron ASTM A48, Class 30Agitator (opt) A05 Chrome ASTM A532, Class III, Type AShaft extension (opt) 17-4 PH ASTM A564

Materials of Construction

Optional features allow customers to tailorthe SHW to specific applications, resultingin the ultimate in heavy duty performance.

Optional Features

• Cooling jacket allows continuous pump operationwith the motor completely unsubmerged

• Suction saver prevents clogging in sumps wheretramp material or very large solids are present

• Quick disconnect guides the SHW into the sumpwith automatic connection to discharge piping.

• Discharge elbow in high chrome iron with heavywall thickness allows for lower cost installation byhaving the correctly designed and sized dischargeelbow for your application

• Sparger ring designed for your application thatallows for improved sump removal of larger solidsby spraying high pressure liquid back into the sump

• Slide bracket allows for easier installation on-siteand provides correct positioning of the pump inyour sump

Sparger ring Slide bracket

Cooling jacket Suction saver

Quick disconnect Discharge elbow

SHW-1206Copyright © Weir Slurry Group, Inc 2006

SHW - 60Hz Supply - 1200 & 1800 rpm

E min. submergence

lugs

D

C

(2) lifting

A

B

280 Motor Frame Dimensions

Pump A B C D E weightinches/mm inches/mm inches/mm inches/mm inches/mm pounds/kg

50-350 55.9/1419 25.0/635 22.1/562 9.6/245 39.6/1006 1800/81775-350 55.7/1416 25.6/650 22.1/562 9.5/241 39.5/1004 1850/840100-350 56.7/1441 26.8/680 22.2/565 10.5/266 40.5/1029 1900/861100-375 57.1/1451 27.3/693 24.1/613 10.9/276 40.9/1038 2000/907150-375 62.2/1580 35.4/898 28.3/720 15.6/395 46.1/1170 2200/998150-450 61.0/1550 35.7/906 29.6/753 14.7/373 44.7/1136 2500/1134



75-500 82.5/2095 32.8/835 28.0/712 10.4/265 48.5/1232 3500/1588100-425 76.1/1933 34.0/864 25.6/651 11.9/303 49.4/1255 3530/1602150-450 79.3/2016 35.6/906 29.6/753 14.7/373 52.5/1336 3625/1645200-450 82.9/2106 39.8/1010 31.2/791 15.8/402 56.2/1427 3760/1706200-525 81.5/2071 40.8/1036 33.5/852 15.5/394 54.8/1393 3922/1779250-550 83.9/2132 48.2/1223 38.9/990 16.6/422 57.2/1452 4655/2112300-400 84.6/2149 49.1/1248 35.7/907 16.9/430 58.5/1488 4137/1877




50-350 47.3/1200 25.0/635 22.1/562 9.6/245 32.6/829 1400/63575-350 47.3/1200 25.6/650 22.1/562 9.5/241 32.6/829 1450/658100-350 48.3/1225 26.9/683 22.2/565 10.5/266 33.6/854 1500/680100-375 48.7/1235 27.3/693 24.1/613 10.9/276 34.1/866 1600/726



50-250 38.5/978 22.2/565 20.5/520 7.5/191 24.6/625 850/38675-250 38.9/988 24.2/615 22.4/570 7.9/201 25.0/635 985/447

Compare weight, compare features, compare performance –the Warman SHW is the most cost effective solution to your slurry pumping requirements.


150-450 103.5/2629 35.6/906 29.6/753 14.7/373 63.2/1605 7370/3343200-450 104.5/2655 39.7/1010 31.2/791 15.8/402 64.2/1631 7500/3402200-525 103.2/2621 40.8/1036 33.5/852 15.5/394 62.8/1595 7670/3480250-550 106.5/2706 48.2/1223 38.9/990 16.6/422 65.5/1664 8400/3811300-600 116.2/2951 51.7/1314 43.5/1105 19.2/489 75.8/1925 8700/3947

SlurryEquipmentSolutions

Weir Minerals North America–Hazleton

225 N Cedar, Hazleton PA 18201PO Box 488, Hazleton PA 18201USA

Tel: 570 455 7711Fax: 570 459 2586www.weirminerals.com

Tota

l hea

d (f

eet)

US gallons per minute (gpm)

Submersible Pumps

Office of origin : Weir Minerals North America, Hazleton Reference : SHW – Submersible pumps

Date : 23 July 2010 Last Issued: 23 July 2010

225 North Cedar St

PO Box 488

Hazleton, PA 18201-0488

USA

Tel: +1 570 455 7711

Fax: +1 570 459 2586

www.weirminerals.com

© 2010 Weir Slurry Group Inc., 2010. Weir Slurry Group Inc. are the owners of the Copyright subsisting in this document and these designs, specifications and instructions.

The document may not be reproduced or copied in whole or in part in any form or by any means without the prior consent in writing of Weir Slurry Group Inc.

Installation, Operation, and Maintenance Manual

General Instructions Applicable to Warman© Submersible Pumps Models SHW, SHW-R and SHW-CS

Robert Kortyna Project Engineer

07/23/2010 Copyright ©2010 Weir Slurry Group, Inc. Page 2 of 34

Weir Minerals Division | Warman

® Model SHW, SHW-R and SHW-CS Pumps

TABLE OF CONTENTS

PREFACE ........................................................................................................................................... 3

SAFETY INFORMATION .................................................................................................................... 4

INTRODUCTION AND SAFETY .................................................................................................................................. 4 MARKING AND APPROVALS .................................................................................................................................... 4 EXPLANATION OF SAFETY TERMINOLOGY AND SYMBOLS.......................................................................................... 4 GENERAL GUIDELINES ........................................................................................................................................... 5

WARRANTY ....................................................................................................................................... 9

MODEL PLATE................................................................................................................................. 10

PRODUCT DESCRIPTION................................................................................................................ 11

DESIGN OF THE PUMP ................................................................................................................... 12

TRANSPORTATION AND STORAGE .............................................................................................. 14

INSTALLATION ................................................................................................................................ 14

HANDLING EQUIPMENT......................................................................................................................................... 14 SAFETY PRECAUTIONS ......................................................................................................................................... 15

ELECTRICAL CONNECTIONS......................................................................................................... 16

PUMP WIRING DIAGRAMS .................................................................................................................................... 17 LEAKAGE AND OVER-TEMPERATURE CONTROL WIRING DIAGRAMS........................................................................ 20

OPERATION ..................................................................................................................................... 21

BEFORE STARTING .............................................................................................................................................. 21

MAINTENANCE ................................................................................................................................ 22

REPLACEMENT PARTS .................................................................................................................. 24

PUMP DISASSEMBLY ..................................................................................................................... 25

OUTLINE AND PUMP DIMENSIONS................................................................................................ 31




WARMAN® SHW SERIES SUBMERSIBLE PUMPS

PREFACE

To ensure long, trouble-free service from your Warman® pump, the instructions contained in this manual must

be followed carefully. When ordering spare parts, it is advisable to provide the pump model, serial number, part description and complete part number.

We reserve the right to make changes or improvements in the design or construction.

For information not covered in this manual, contact:

Customer Service Department Weir Minerals 225 N Cedar P.O. Box 488 Hazleton PA, 18201 USA Telephone: (570) 455-7711 Fax: (570) 459-2586 PUMP ASSEMBLY

The following pages contain step-by-step instructions for correct assembly and maintenance of type SHW, SHW-CS and SHW-R Warman

® pumps.

The manual is written in a disassembly format. We recommend reading through applicable sections prior to beginning assembly to ensure safety concerns are addressed.

PUMP INFORMATION

Record this information: It will be critical to have this information for the accurate identification of spare parts which may be required later.

Pump Size / Type:

Model:

Serial Number:

Date Received:

Date Placed in Service:




SAFETY INFORMATION

Introduction and Safety Warman

® submersible pumps, when properly installed and operated, and when given reasonable care and

maintenance, will operate satisfactorily for a long period of time. The following paragraphs outline the general principles that should be considered to ensure trouble-free pump operation. Warman

® submersible pumps are built in a variety of designs and materials and for many different services. The

manufacturer’s instruction manual should be studied carefully and followed, as there may be specific requirements for a particular machine or application that cannot be covered in a general discussion. The installation and operation manual and/or special instructions included in the shipment should be read thoroughly before installing or operating the pump. All instructions regarding maintenance should be retained for reference.

Marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform to the applicable CE marking directives covering machinery and, where applicable, Canadian Standards International compliance (CSA), and equipment for potentially explosive atmospheres (FM Approvals). Where applicable, the directives and any additional approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable, this document incorporates information relevant to these directives and approvals. To confirm applicable approvals and CE marking, check the model plate markings and the certification.

Safety Legal requirements and local regulations may differ substantially with regard to particular safety requirements and may be regularly modified by relevant authorities without notice. As a consequence, applicable laws and regulations should be consulted to ensure compliance. The following cannot be guaranteed as to its completeness or continuing accuracy.

Explanation of safety terminology and symbols

These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are:

This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.

This symbol indicates safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.

This symbol indicates safety instructions where non-compliance would affect personal safety and could result in the loss of life.

This is a general safety alert symbol to indicate the potential risk of personal injury.




This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates safety instructions where non-compliance may result in minor or moderate personal injury.

This symbol indicates safety instructions where non-compliance could result in damage to the equipment or property.

This symbol indicates explosive atmosphere zone marking according. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

This sign is not a safety symbol but indicates an important instruction in the assembly and/or operation process.

General guidelines

These Instructions must always be kept close to the pump’s operating location or directly with the pump.

Warman

® submersible pumps are designed, developed and manufactured with state of the art technologies in

modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements. Weir Minerals is committed to continuous quality improvements and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements, applicable safety and health laws/regulations.

These Instructions should be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety noted in the instructions have been met. Information in these User Instructions is believed to be reliable. In spite of all the efforts to provide sound and all necessary information, the content of this manual may appear insufficient and is not guaranteed as to its completeness or accuracy. For the safety of operating personnel, please note that the information supplied in this manual only applies to the fitting of genuine Warman

® parts and Warman

® recommended components to Warman

® submersible

pumps. Weir Minerals manufactures products to exacting International Quality Management system Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Weir Minerals cannot test parts and accessories sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized parts and accessories is considered




misuse. Damage or failure caused by misuse is not covered by our warranty. In addition, and modification of Weir Minerals products or removal of original components may impair the safety of these products in their use.

The pumps must not be operated beyond the allowable limits of pressure, temperature, and speed specified for the application. These limits are dependent on the pump type, configuration and materials used. If there is any doubt as to the suitability of the product for the application intended, contact Weir Minerals for advice, quoting the serial number. If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature, specific gravity or duty), it is requested that the user seek the manufacturer’s written agreement before startup.

Personnel qualification and training All personnel involved in the operation, installation, inspection, and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer/supplier to provide applicable training. Always coordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws and regulations.

Safety action This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and to equipment.

WEIR MINERALS WOULD LIKE TO BRING TO YOUR ATTENTION THE POTENTIAL HAZARD CAUSED BY THE CONTINUED OPERATION OF CENTRIFUGAL PUMPS WHEN THE INTAKE AND DISCHARGE ARE BLOCKED. EXTREME HEAT IS GENERATED AND RESULTS IN VAPORIZATION

OF THE ENTRAPPED LIQUID. THIS CAN RESULT IN A LIFE THREATENING EXPLOSION. The operation of centrifugal pumps on slurry applications can increase this potential hazard due to the nature of the material being pumped. The additional hazard believed to be presented by slurry applications stem from the possibility of solids blocking the pump discharge and remaining undetected. This situation has been known in some instances to lead to the intake side of the pump also becoming blocked with solids. The continued operation of the pump under these circumstances can be extremely dangerous. If you have an installation that may be prone to this occurrence, we suggest you adopt measures to prevent this blockage situation

The WARMAN® SUBMERSIBLE PUMP is a piece of ROTATING EQUIPMENT which

CONTAINS PRESSURE under service conditions. All standard safety precautions for such equipment should be followed before and during installation, operation, and maintenance.

For AUXILIARY EQUIPMENT standard safety precautions should be followed and appropriate instruction manuals consulted before and during installation, operation, adjustment and maintenance.

DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING LIQUID TO VAPORIZE. Personal injury and equipment damage could result from the high temperature and pressure created.

DANGER




DO NOT APPLY HEAT TO THE IMPELLER NUT IN AN EFFORT TO LOOSEN PRIOR TO REMOVAL. Damage to the Impeller can occur. Personal injury and damage to equipment could occur as a result of an explosion.

THERMAL SHOCK Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal shock may cause damage to the internal components and cause failure of the pump casing.

DRIVER ROTATION MUST BE CHECKED before final installation. Personal injury and damage to equipment could result from operating the pump in the wrong direction. Do not touch rotating members with hand to find the direction of rotation.

DO NOT START A PUMP that is rotating in reverse, such as the backward rotation caused by slurry runback. Personal injury and damage to equipment could result.

ENSURE THAT IMPELLER IS TIGHT ON THE SHAFT before any start-up, i.e. all components on the shaft between the impeller and the pump end bearing butt metal to metal against each other without any gap. Note that gaps may form when the pump experiences duty conditions conducive to unscrewing of the impeller, such as excessive runback, high intake pressure, motor braking, etc.

NEVER PERFORM MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER. Power to the electric motor must be isolated and tagged out.

THE PUMP MUST BE FULLY ISOLATED before any maintenance work, inspection or troubleshooting involving work on sections which are potentially pressurized (e.g. casing, connected pipework). It must be proven that the discharge opening is totally isolated from all potentially pressurized connections and that it is, and can only be exposed to atmospheric pressure.

DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous.

HANDLING PUMP AND COMPONENTS The pump is equipped with lifting lugs that are an integral part of the motor housing or cover for lifting. These should be used for lifting the pump assembly.

• Lifting devices of adequate capacity must be used in conjunction with these assembly and maintenance instructions wherever they are required to be used.

• Sound, safe workshop practices should be applied during all assembly and maintenance work.

• Personnel should never work under suspended loads.

DO NOT APPLY HEAT TO HIGH CHROME COMPONENTS. This can cause cracks, residual stresses, and changes the fracture toughness of the parent material. This may lead to catastrophic failure and could result in personal injury and equipment damage even when operating within recommended speed and pressure limits.

CASTINGS can be made from materials that are brittle and have a low thermal shock resistance. Attempts to repair or rebuild by welding procedures may cause catastrophic failure. Contact factory for information related to weld repairs.

DANGER




AVOID CONTAMINATION

• LEAKAGE from worn pump components or seals may cause water and/or soil contamination.

• LIQUID WASTE DISPOSAL from servicing of pumps or stagnant water from pumps stored for long periods, may cause water and/or soil contamination.

Mixing of NEW AND WORN PUMP PARTS may increase the incidence of premature pump wear and leakage. All METAL MATING FACES MUST BE CLEANED of dirt, rust, paint and other adhering substances prior to pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to catastrophic failure of parts.

Large FOREIGN OBJECTS OR TRAMP entering a pump will increase the incidence of higher wear and / or damage to the pump.

Large VARIATIONS IN SLURRY PROPERTIES may lead to accelerated rates of wear and corrosion of pump components, e.g.

• Wear increases exponentially with velocity and slurry particle size.

• Corrosion rate doubles for every 10 degree Celsius (18 degrees Fahrenheit) increase in slurry temperature.

• Corrosion rate increases exponentially as slurry pH decreases.




WARRANTY LIMITED WARRANTIES FOR WMNA PRODUCTS, REPLACEMENT PARTS, REPAIRED PARTS AND REFURBISHED PARTS AND PRODUCTS: (a) Weir Minerals North America (WMNA) warrants that: (i) Products: New Products manufactured by WMNA shall be free of defects in material and workmanship for a period of one (1) year from the date of shipment of the Product by WMNA to Buyer; (ii) Parts: New replacement parts manufactured by WMNA shall be free of defects in material and workmanship for a period of one (1) year from the date of shipment of the part by WMNA to Buyer; (iii) Repaired Parts: Parts for Products or subassemblies of Products which are repaired by WMNA shall be free of defects in material and workmanship for a period of three (3) months from the date of shipment of the repaired item to Buyer; and (iv) Refurbished Products or Subassemblies: Products or subassemblies of Products which are refurbished by WMNA due to ordinary wear and tear shall be free of defects in material and workmanship for a period of three (3) months from the date of shipment of refurbished Products or subassemblies. (b) Any Product, part, repaired part or refurbished Product or refurbished subassembly which is or becomes defective during the warranty period shall be repaired or replaced by WMNA free of charge, F.O.B. Madison, Wisconsin, or a repair facility designated by WMNA, provided that (i) written notice of such defect is given by Buyer to WMNA as soon as the defect is discovered, (ii) the Product is operated in accordance with the conditions for which it was designed, (iii) no alterations or substitutions are made in the Product by Buyer, (iv) if requested by WMNA, the part or Product to be repaired or replaced is returned to WMNA at Buyer's expense after having received WMNA's written authority to do so, and (v) any parts or Products which are contaminated with a hazardous chemical are first decontaminated and shipped with the MSDS sheets and certificate of decontamination. (c) No payment or allowance will be made to Buyer for repairs or alterations made to the equipment by Buyer or by others at Buyer's direction, unless WMNA's prior written approval is obtained. (d) WMNA does not warrant components of WMNA Products, which are not manufactured by WMNA. Non-warranted items include, but are not limited to, electric motors, gear reducers, "V" belt drives, other drives, couplings, mechanical seals, valve actuators, solenoid valves, limit switches, and proximity switches, etc. Any warranty provided by the manufacturer or supplier of such components shall be and hereby is assigned by WMNA to Buyer without recourse. LIMITATION OF DAMAGES FOR BREACH OF WARRANTY: WMNA's liability for breach of warranty shall not exceed an amount equal to the purchase price paid by Buyer. WMNA shall not be responsible for any indirect or consequential damages arising out of any breach of warranty. The assertion by Buyer of a breach of warranty by WMNA shall not entitle Buyer to withhold or deduct any amount from sums owed by Buyer to WMNA. EXCLUSIVE WARRANTIES: THE FOREGOING WARRANTIES FOR PRODUCTS, REFURBISHMENTS AND PARTS ARE EXCLUSIVE AND THERE ARE NO OTHER WARRANTIES BY WMNA, EITHER EXPRESS OR IMPLIED, INCLUDING NO IMPLIED WARRANTY OF MERCHANTABILITY AND NO IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. NO REPRESENTATION BY ANY SALES REPRESENTATIVE, DISTRIBUTOR, SALESMAN, OR EMPLOYEE OF WMNA SHALL ALTER OR AMEND THE LIMITED WARRANTIES UNLESS SUCH ALTERATION OR AMENDMENT IS CONTAINED IN A WRITTEN PROPOSAL, LABELED "WARRANTY" AND SIGNED BY AN AUTHORIZED OFFICER OF WMNA. IF PERFORMANCE IS QUOTED BY WMNA, IT WILL BE BASED ON ITS EXPERIENCE AND WILL BE SUCH AS WMNA WOULD EXPECT TO OBTAIN ON A TEST BUT SUCH QUOTATION DOES NOT CONSTITUTE A WARRANTY AS TO PERFORMANCE.




MODEL PLATE

The general model plate for the SHW is either imperial or metric in nature. (See examples below)

Model plates can also carry approval information or may be an additional model plate if more information is required (see examples below)




PRODUCT DESCRIPTION Introduction Thank you for buying a submersible Weir Minerals pump. In this Installation, Care and Maintenance manual you will find general information on how to install and service the pump to give it a long and reliable life. Application This Installation, Care and Maintenance manual applies to the submersible Weir Minerals pumps:

• SHW

• SHW-R

• SHW-CS The pump is intended to be used for:

• Pumping of water containing abrasive particles

• Pumping of ground water

• Pumping of slurries Installation alternatives Liquid temperature: Max. 40°C (104°F) Also available with an optional cooling jacket for liquid temperatures up to 70°C (158°F). Min. 3°C (5°F) higher than liquid freezing point. Solids passing size: various – depends on impeller design Depth of immersion: Max. 30 m (100 ft)

Explosion proof product Max. 23 m (75 ft) Lowest liquid level: Standard product – See outline dimensional drawing page 30 With optional cooling jacket - Complete mechanical seal housing to be submerged




DESIGN OF THE PUMP

The Warman

® SHW is a submersible, electric motor-driven slurry pump.

1. Motor Squirrel-cage 3-phase induction motor for 50 Hz or 60 Hz. The motor is started by means of direct on-line. The motor can be run continuously or intermittently with a maximum of 6 evenly spaced starts per hour. The stator is insulated in accordance with class F (155°C, 311°F) or optional class H (180°C, 360°F). The motor is designed to supply its rated output at ±5 % variation of the rated voltage. Without overheating the motor, ±10 % variation of the rated voltage can be accepted provided that the motor does not run continuously at full load. The motor is designed to operate with a voltage imbalance of up to 2 % between the phases. 2. Bearings The support bearing of the shaft is a deep groove ball bearing. The main bearing of the shaft is a double row angular contact or duplex ball bearing. 3. Mechanical seal unit The pump has one shaft mechanical seal unit consisting of two sets of independently operating seal faces. Inner seal: carbon / silicon carbide Outer seal: silicon carbide / silicon carbide 4. Monitoring equipment Thermal: The stator incorporates three thermostats connected in series. The thermostats are a normally closed type that will open in the event an over temperature condition exist in the motor windings. The thermostats shall be connected via the control cable to a Weir Minerals three light box or equivalent unit (see control cable wiring diagram). The thermostats automatically reset once the temperature in the winding decreases. This will allow the pump to be restarted. The thermal contacts: open at 160°C (320°F) for class F insulation, 200°C (392°F) for class H insulation. Moisture: The stator housing also contains two moisture sensors that activate an alarm when moisture is detected in the stator housing. The sensors shall be connected to a Weir Minerals three light box or equivalent unit. 5. Cooling (without cooling jacket) The pump is cooled by the liquid surrounding the motor housing. For lowest liquid level, see outline dimensional drawing page 30 or general arrangement drawing for specific serial number. 6. Mechanical seal housing Gulf Harmony 32 oil lubricates and cools the mechanical seal unit and acts as a buffer between the pumped media and the electric motor. 7. Shaft The shaft is delivered with the rotor as an integral part. Shaft material: stainless steel.




8. Cooling (with optional cooling jacket) The motor is cooled by a customer supplied fluid circulating through the optional cooling jacket. This allows a lower pumping level and/or higher allowable ambient temperature. See lowest liquid level allowable on page 11. See table below for recommended flow rates.

Frame size Flow @ or below

27°C ( 80°F)

210 0.7-0.9 m3/hr (3-4 GPM)

250 0.7-0.9 m3/hr (3-4 GPM)

280 0.7-0.9 m3/hr (3-4 GPM)

360 1.1-1.8 m3/hr (5-8 GPM)

9. Impeller Standard Material: High chrome alloyed white cast iron 10. Casing / suction head Standard Material: High chrome alloyed white cast iron Open or closed designs, dependant on pump selection




TRANSPORTATION AND STORAGE

The pump may be transported in a vertical or horizontal position. Make sure that the pump cannot roll or fall over.

Always lift the pump by its lifting lugs, never by the motor cable or the discharge pipe or hose. The pump is frostproof as long as it is operating or is immersed. If the pump is hoisted from the sump when the temperature is below the freezing point, the impeller and shaft seal may freeze. A frozen impeller and shaft seal can be thawed by allowing the pump to stand immersed in the liquid for a short period before it is started. Never use a naked flame to thaw the pump. The pump should run for a few seconds after being taken up in order to expel all remaining water from the hydraulic end.

Short term storage (less than 60 days) The pump must be stored in a vertical position regardless of shipping orientation. The pump should be stored in a clean, dry location and be protected from dirt and foreign matter. The storage area should also be free from vibration. Cable ends should be protected to prevent moisture intrusion.

Long term storage (greater than 60 days) For longer periods of storage, the pump must be protected against moisture and heat and stored in a vertical position. If the pump is to be stored outside or in an excessively unfavorable environment the pump and cables must be covered with a waterproof covering that will allow proper air circulation. Cable ends should be protected to prevent moisture intrusion. It is mandatory that the impeller be rotated by hand at least ten (10) revolutions per month to prevent the shaft seals from sticking together. After a long period of storage, the pump should be inspected before it is put into operation. Pay special attention to the shaft below the mechanical seal and the cables. See Maintenance section. Follow the instructions under the heading "Before starting".

INSTALLATION

Handling equipment Always pay extra attention to safety aspects when working with lifting equipment. Lifting equipment is required for handling the pump. The lifting chain and the shackle should be in stainless steel and inspected every year.

— Stay clear of suspended loads. — Always lift the pump by its lifting lugs – never by the motor cable or discharge hose/pipe.

The minim The minimum height between the lifting hook and the floor shall be sufficient to lift the pump out of the sump. The lifting equipment shall be able to hoist the pump straight up and down in the sump, preferably without the need for resetting the lifting hook. Oversized lifting equipment could cause damage if the pump should stick when being lifted. Make sure that the lifting equipment is securely anchored and in good condition. Check that the lifting handle and chain are in good condition.




To ensure proper installation, please see the dimensions on the dimensional drawing.

The end of the cable must not be submerged. It must be above flood level, as water could penetrate through the cable into the junction box or the motor.

For automatic operation of the pump (level control), it is recommended that the level regulators should be used

at low voltage. The data sheet delivered with the regulators gives the permissible voltage.

Local rules may specify otherwise.

Clean out all debris from the sump before the pump is lowered down and the station is started.

— Minimum stop level should be according to the dimensional drawing. — The pump must never run dry.

Safety precautions In order to minimize the risk of accidents in connection with service and installation work, the following rules should be followed: 1. Never work alone. Use a lifting harness, safety line and a respirator as required. Do not ignore the risk of drowning. 2. Make sure there are no dangerous gases within the work area. 3. Check the explosion risk before welding or using electric hand tools. 4. Before the pump is installed check that the cable and cable entry have not been damaged during the transportation. 5. Observe strict cleanliness. Do not ignore health hazards. 6. Bear in mind the risk of electrical accidents. 7. Make sure that the lifting equipment is in good condition and comply to local ordinances. 8. Provide a suitable barrier around the work area (guard rail). 9. Make sure you have a clear path of retreat. 10. Use all appropriate PPE. 11. A first-aid kit must be close at hand. 12. Note that special rules apply to installation in explosive atmosphere. Follow all health and safety rules and local codes and ordinances. Installation alternatives Cooling jacket: verify coolant supply connections and flow prior to installing pump




ELECTRICAL CONNECTIONS

Before starting work on the pump, make sure that the pump and the control panel are isolated from the power supply and cannot be energized. All electrical equipment must be earthed (grounded). This applies to both pump equipment and any monitoring equipment. Failure to heed this warning may cause a lethal accident. Make sure that the earth (ground) lead is correctly connected by testing it.

� All electrical work shall be carried out under the supervision of an authorized electrician. Local codes and regulations shall be complied with.

� Check the model plate to determine which voltage supply is valid for your pump. � Check that the main voltage and frequency agree with the specifications on the pump data plate.

� The user must select a motor starter and over current protection suitable for this motor and its application. Consult motor starter application data as well as the National Electric Code and/or other local codes.

� Connect the motor cable to the starter equipment as illustrated in the wiring diagrams.

Leads that are not in use must be isolated. The cable should be replaced if the outer sheath is damaged. Contact a Weir Minerals authorized service facility. Make sure that the cable does not have any sharp bends and is not pinched. Under no circumstances may the starter equipment be installed in the sump.

For safety reasons, the earth (ground) lead should be approx. 100 mm (4.0") longer than the phase lead. If the motor cable is jerked loose by mistake, the earth (ground) lead should be the last lead to come loose from its terminal. This applies to both ends of the cable.

Bear in mind the risk of electrical shock and the risk of explosion if the electrical connections are not correctly carried out.




Pump Wiring Diagrams

Power and control cables

• Consult general arrangement drawing provided with your pump or markings on the pump cables for actual cable type.

Type “W” Power Cable

Type “G-GC” Power Cable




Type “SHD-GC” Power Cable

Type “Protomont HD” Power Cable




Type “Protomont KON” Power Cable




Leakage and Over-temperature control Wiring Diagrams Weir Minerals 3 Light Box for both Over Temperature and Moisture detection.

Warrick Model 2820 for Moisture detection only

• W1 and REF are connected to the moisture sensors.

• Load A and B refer to motor start circuit or similar device




OPERATION

Before starting

Before starting work on the pump, make sure that the pump is isolated from the power

supply and cannot be energized. This applies to the control circuit as well.

In some installations the pump surface and the surrounding liquid may be hot. Bear in

mind the risk of burn injuries.

Make sure that the pump cannot roll or fall over and injure people or damage property.

� Check that the visible parts of the pump and installation are undamaged and in good condition.

� Remove the fuses or open the circuit breaker and check that the impeller can be rotated by hand.

� Verify that the supply voltage matches the pump data plate voltage rating.

� Conduct insulation integrity check.

� Conduct phase to phase resistance check.

� Check that the monitoring equipment works.

� Check the direction of rotation. The impeller shall rotate clockwise, as viewed from above.

� Transpose two phase leads if the impeller rotates in the wrong direction.

� If supplied with Dual power cables, tie like color wires together when connecting to power source.

Operation During operation, observe the motor’s performance. It should run smoothly with little noise. Motor operation may stop for one of the following trip conditions:

1. If moisture infiltrates the motor or mechanical seal housing, the moisture detector circuit will activate. 2. If the motor overheats, the thermal protection circuit will activate. 3. Other condition detected by motor starter (over current, overvoltage, etc. If equipped)

Unbalanced voltage or single phase operation of a poly phase motor may cause excessive heating and ultimate

failure. A slight unbalance of voltage applied to a poly phase motor will cause large unbalance currents and

resultant overheating. Periodic checks of phase voltage, frequency and power consumption of a motor

(measured at the motor starter) while in operation are recommended; such checks assure the correctness of

frequency and voltage applied to the motor and yield an indication of the performance of the complete pump.

Any serious deviations should be investigated and corrected. If a problem occurs, contact your Weir Minerals

representative or the factory.

Should the terminal cover assembly or cables be damaged or their integrity be in question, it is required that a

replacement terminal cover assembly be ordered and installed prior to further operation.

Cleaning If the pump has to be stopped after it has been running in heavy slurry, let it run for a while in clean water, or

flush it through the discharge connection. If clay, cement or other similar dirt is left in the pump it may clog the

impeller and seal, hampering the pump’s operation. During a longer period out of operation, the pump must be

test run every other month to prevent the mechanical seals from sticking together.




MAINTENANCE

Warman

® pumps are of sturdy construction and, when correctly assembled and applied, will provide long,

trouble-free service with a minimum amount of maintenance. As operating conditions can vary widely between pump installations it is nearly impossible to recommend a single schedule for preventative maintenance. In order to determine when the pump will require parts change-out to prevent breakdown a regular inspection period should be instituted. During this period an inspection of the pump is made, various conditions are recorded an preventive maintenance procedures are performed. Weir Minerals also recommends recording hours of operation. If disassembly of the pump is required/performed for any reason, replace all gaskets and/or seals.

Motor insulation resistance Check with a megaohm meter on a regular basis. If readings become less than 10 megaohms consult your local representative or the factory for corrective actions.

Impeller clearance Pump performance changes inversely with the clearance between the impeller and the suction head. Typically, as the pump wears the clearance increases and the pump efficiency drops. Often an increase in motor current indicates wear has occurred between the impeller and suction head. Impeller clearance can be adjusted by changing the shim/gasket(s) located between the suction head and casing. See pump disassembly section of this manual for additional information. Before restarting, be sure impeller turns freely and all fasteners are tight.

Lubrication Bearings:

• 210, 250 and 280 Frame o Sealed for life, requiring no relubrication o Life expectancy 17,500 hours

• 360 Frame o Relubricate every 8000 hours of operation or once per year

� Use Mobilith SHC 100 grease only � Lubricant quantity

• Thrust bearing – 2.0 oz

• Radial bearing – 1.5oz o Life expectancy 17,500 hours

Mechanical seal housing:

• The level and condition of the barrier oil in the mechanical seal housing should be evaluated each time maintenance is performed. The original oil (Gulf Harmony 32) is clear. If the oil appears to be milky, discoloured, or dirty it should be replaced.

• Oil change interval 8000 hours • Oil capacity by frame size

o 210 1.9 liters (0.50 gallons) o 250 2.8 liters (0.75 gallons) o 280 3.75 liters (1.00 gallons) o 360 6.6 liters (1.75 gallons)




Mechanical Seal When maintenance is performed other than the oil change, check the shaft below the mechanical seal for evidence of oil leakage. If oil is leaking, drain the oil and check the mechanical seal faces and o-rings. Replace the mechanical seal if there are scratches, cracks or gouges on the faces or the o-rings are damaged.

Motor leads Check the condition of the power and control cables.




REPLACEMENT PARTS

You can use Weir Minerals components diagrams coupled with your pump specific spare parts list to determine

part numbers for your pump. The following components diagram and your pump serial number can also be used to obtain this information from your Weir Minerals representative or the factory.




PUMP DISASSEMBLY

Worn agitator, impeller and/or pump housings can have very sharp edges.

Use protective gloves!

• Place pump horizontally

• Remove agitator if applicable

• If pump is fitted with a strainer basket

• Remove strainer basket fasteners

• Remove strainer basket

210 frame pumps use the casing bolts to retain the strainer. Use caution when

removing bolts to ensure suction head remains in place.




• Remove suction head fasteners

• Remove Suction head

• Remove Suction head shim/gasket(s)

Shim/gasket(s) used to set impeller clearance at factory recommended 0.76mm (0.030 in)

• Remove shaft extension or impeller nut(s)*

• Pull keyed impeller off shaft

210 frame pumps have either one impeller nut or a shaft extension. All other pumps have two impeller

nuts or a nut and shaft extension




• Remove casing / mechanical seal housing bolts

• Remove casing

• Remove slinger locking screw

• Loosen slinger clamping bolt

• Remove slinger and V-Ring




Mechanical seal housing oil

Oil change interval – 800 hours

Use only Gulf Harmony 32

• Place pump in a vertical position

• Remove the seal drain plug

• Remove fill and vent plugs to vent chamber

o Check oil for water

� If present check seal and joints

Refilling mechanical seal housing

• Replace drain plug

• Fill until oil reaches the fill hole

• Replace fill and vent plugs




• Remove mechanical seal cover and o-ring

• Remove stationary seat portion of mechanical seal from mechanical seal cover

o Verify seal anti rotation pin in mechanical seal cover is intact (Detail “C”)

• Loosen mechanical seal set screw (located in the rotating assembly)

• Slide rotating portion of mechanical seal off shaft

• Remove stationary seat portion of mechanical seal from mechanical seal housing

o Verify seal anti rotation pin in mechanical seal housing is intact (Detail “A”)

Reinstallation of Mechanical seal

• Install stationary seats and wipe with clean lint free cloth or alcohol wipe

• Slide rotating assembly on shaft after wiping seal faces

• Secure rotating assembly to shaft by tightening set screw on seal into locating hole in the shaft

• Reinstall mechanical seal cover




Terminal cover replacement

Terminal cover must be replaced as a complete unit.

Bear in mind the risk of electrical shock and the risk of explosion if the electrical connections are not correctly carried out.

Install o-ring prior to making electrical connections

• Control cables should be connected to like color cables from the stator housing using standard

wire nuts • Power cables and grounds should be connected to the motor leads and appropriate grounding

points o Connect using appropriately sized “SPA” type connectors and insulated with “Shrink-

Kon” HS series shrink tubing o Or using appropriately sized “AMT” connectors from Thomas & Betts




OUTLINE AND PUMP DIMENSIONS




TROUBLESHOOTING




The information in this manual has been checked and is believed to be accurate and reliable. HOWEVER, NO

RESPONSIBILITY IS ASSUMED BY WEIR SLURRY GROUP FOR ITS USE OR FOR ANY INACCURACIES.

Specifications are subject to change without notice. WEIR SLURRY GROUP DOES NOT ASSUME ANY

LIABILITY ARISING OUT OF USE OR OTHER APPLICATION OF ANY PRODUCT DESCRIBED HEREIN. This

document does not convey any license under Weir Slurry Group’s patents or the rights of others.

REVISION HISTORY

Revision Level Principal Changes Date of Publication

A First Publication June 2010

B Added oil quantities July 2010

C

D

E

F

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