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VENDOR DOCUMENT IDENTIFICATION Sales order no. 201253 Pump type TZPM 1200 I.O.M. Instructions Typical

VENDOR DOCUMENT IDENTIFICATION

Sales order no.

201253

Pump type

TZPM 1200 I.O.M. Instructions Typical

Document title

Revision

0

EPSN document code

201253-IOMT

CLIENT DOCUMENT IDENTIFICATION

P.O. No.

500P-MR-315-01

Purchaser order Title

Esperanza

Project

Esperanza

Project No.

C-550

Client Type code

X009

Client document code

X009

Client

Esperanza

Pumptype

TZPM 1200

SUBMISSION STATUS

 

0

02-feb-09

for approval

MM

Rev.

Date

Description of issue

Sign.

Weir Minerals Netherlands

P.O. Box 249, 5900 AE Venlo, the Netherlands

Tel:

+31(0)77 3895200

Egtenrayseweg 9, NL-5928 PH Venlo

Fax:

+31(0)77 3824844

4495

4495

Email: weir@weirminerals.com

Registration No.: 12032525

WWW: http://www.weirminerals.com

No.: 12032525 WWW: http://www.weirminerals.com Installation, Operating and Maintenance Manual WEIR Pump
No.: 12032525 WWW: http://www.weirminerals.com Installation, Operating and Maintenance Manual WEIR Pump

Installation, Operating and Maintenance Manual

WEIR Pump type

: TZPM 1200

WEIR Pump number

:

WEIR Project name

:

WEIR Document number

:

Customer P.O. number

:

Copyright © Weir Minerals Netherlands b.v. 2008.

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.

Preface

Preface

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1

Preface

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This pump is developed by Weir Minerals Netherlands.

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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:

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Transport

Installation

Operation, start and stop procedure

Maintenance

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This equipment, supplied by Weir Minerals Netherlands, 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 is required.

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overview @ 5\mod_1225107795665_0.doc @ 39770 Pos: 1.3 /GEHO/Heading/H2/#.# Revision form @
overview @ 5\mod_1225107795665_0.doc @ 39770 Pos: 1.3 /GEHO/Heading/H2/#.# Revision form @

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Preface

Preface

1.1 Revision form

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Rev. No.

Chapter

Description

By

Checked

Date

R00.EN

 

Preliminary release Manual Transport and Installation

JOH

R00.EN   Preliminary release Manual Transport and Installation JOH  
 

R01.EN

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Final release Installation, Operating and Maintenance Manual

JOH

page --- @ 0\mod_1133257917306_0.doc @ 151   Final release Installation, Operating and Maintenance Manual JOH  
 

Contents

Contents

Pos: 3 /GEHO/General/Special formats/Table of contents @ 0\mod_1133257649241_31.doc @ 147

2

Contents

1 Preface

1.1 Revision form

1.1

1.2

2 Contents

2.1

3 SAFETY

3.1

3.1 Safety symbols

3.1

3.2 Important information

3.2

3.3 Intended use

3.3

3.4 General safety instructions

3.3

3.5 Qualified workers

3.3

3.6 Working

on the pump

3.3

3.7 Efficient

use

3.3

3.8 Safety equipment

3.3

3.8.1 Safety related documentation

3.3

3.8.2 CE conformity

3.3

3.8.3 Emergency stop button

3.4

3.8.4 Safety covers and safety guards

3.4

4 Technical data

4.1

4.1 Project 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

4.3

4.5 Tightening torques

4.5

4.5.1 General torques

4.5

4.5.2 Foundation bolt torques according to DIN 529

4.5

4.5.3 Special torques

4.5

4.6 Auxiliary connections and lubrication data

4.7

4.7 Drawings + lists + instruments

4.8

5 Description

5.1

5.1 Introduction

5.1

5.2 Working principle

5.2

5.2.1 Suction stroke

5.2

5.2.2 Discharge stroke

5.2

5.3 Drive unit

5.3

Contents

Contents

5.4 Power end

5.4.1 Lubrication unit

5.5 Liquid end

5.3

5.3

5.3

5.5.1 The propelling liquid section 5.4

5.5.2 The slurry section

5.4

5.5.3 Piston unit 5.4

5.5.4 Propelling liquid control system 5.5

5.5.5 Flushing unit

5.6

5.5.6 Diaphragm housing unit

5.6

5.5.7 Suction valve unit

5.7

5.5.8 Discharge valve unit 5.7

5.5.9 Suction pulsation dampener 5.7

5.5.10 Discharge pulsation dampener

5.7

5.5.11 Pressure limitation system

5.8

5.6 Pump control system

6 Transport and installation

6.1 Transport and lifting

5.9

6.1

6.1

6.1.1 Weights and weight limits

6.1

6.1.2 Transport the packed installation

6.2

6.1.3 Pump

6.2

6.1.4 Drive unit

6.3

6.1.5 Drive unit frame

6.3

6.1.6 Smaller parts

6.3

6.2 Installation

6.4

6.2.1 Foundation 6.4

6.2.2 Mount and level the pump 6.5

6.2.3 Drive unit

6.2.4 Safety regulations and instructions for nitrogen 6.11

6.6

6.2.5 Pre-charging the suction pulsation dampener, set-point instructions 6.12

6.2.6 Pre-charging the discharge pulsation dampener, set-point instructions

6.16

6.2.7 Pre-charging an accumulator with nitrogen

6.21

7 Operation, Start-up + Start + Stop procedures

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

7.1

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 Procedure pre-charging a pulsation dampener with nitrogen

7.3

7.1.5 Pre-charging an accumulator with nitrogen

7.3

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

7.4.1 Pump operation by local control at the GEHO Touch Panel

7.8

7.8

Contents

Contents

7.4.2 Pump operation by remote control, supplied by others

7.5 Start procedures

7.8

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 button procedure, if LOCAL operated

7.14

7.6.3 STOP by remote control

7.14

7.6.4 STOP for flushing procedure

7.15

7.6.5 STOP for maintenance procedure

7.16

8 Maintenance

8.1

8.1 Maintenance

safety instructions

8.1

8.2 Maintenance

checkpoints

8.2

8.3 Lubrication system

8.12

8.3.1 Check the oil level

8.12

8.3.2 Change the oil filter

8.12

8.3.3 Clean the lubrication oil sump

8.12

8.3.4 Replace the pump lubrication oil and the oil suction filter

8.13

8.3.5 Replace the venting filter at the pump power end

8.13

8.4 Propelling liquid system

8.13

8.4.1 Replace the venting filter at the propelling liquid system

8.13

8.4.2 (Dis)assemble the discharge filter of the propelling liquid system

8.14

8.4.3 Disassemble the suction filter at the propelling liquid tank

8.14

8.4.4 Assemble the suction filter at the propelling liquid tank

8.14

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 Special tools

10.1

10.3

10.1.1 Socket wrench

10.3

10.1.2 Air driven hydraulic pump

10.3

10.2 Valves, discharge line, angular model

10.2.1 Valve housing cover

10.5

10.5

Contents

Contents

10.2.2 Conical valve

10.6

10.2.3 Valve seat

10.7

10.3 Valves, suction side, inline model

10.9

10.3.1 Valve housing cover

10.9

10.3.2 Conical valve

10.11

10.3.3 Valve seat

10.14

10.3.4 Conical valve assembly

10.15

10.4 Piston unit

10.17

10.4.1 Disassembly

10.17

10.4.2 Assembly

10.19

10.5 Diaphragm housing unit

10.20

10.5.1 Disassembly

10.20

10.5.2 Assembly

10.25

10.6 Pulsation

dampener

10.29

10.6.1 Diaphragm removing

10.30

10.6.2 Diaphragm assembly

10.30

10.7 Nitrogen filling device

10.34

10.8 Frame unit

10.34

10.9 Drive unit

10.34

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

11.1

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

12.1

13 Appendix: Electrical information

13.1

14 Appendix: Catalogue information

14.1

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SAFETY

SAFETY

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3

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3.1 Safety symbols

SAFETY

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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 serious injuries

DANGER

Dangerous situation

Death or 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:

Attention

Possible harmful

Possible damage to:

The equipment

The environment

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Note or

Application hints and other useful information

No signal word indicating a dangerous or harmful situation

Information

SAFETY

SAFETY

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3.2 Important information

Pos: 5.6 /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.

law) in the jurisdiction in which the machine is installed. Pos: 5.7 /--- Page break ---
law) in the jurisdiction in which the machine is installed. Pos: 5.7 /--- Page break ---
law) in the jurisdiction in which the machine is installed. Pos: 5.7 /--- Page break ---

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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.

SAFETY

SAFETY

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3.3 Intended use

Pos: 5.9 /GEHO/Safety/Product Safety/Intended use @ 0\mod_1138263117509_31.doc @ 1914

This pump 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.

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3.4 General safety instructions

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Always obey local safety regulations and instructions.

Never cause a potentially dangerous situation.

Never touch moving parts.

Never loosen parts under pressure.

Never touch parts with high temperature.

Never touch parts under electrical power.

Never touch parts which contain dangerous or poisonous media.

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3.5 Qualified workers

Pos: 5.13 /GEHO/Safety/Product Safety/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.

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3.6 Working on the pump

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Switch off the main power supply and secure the equipment against switching on.

Never loosen any parts containing pressure, hot or dangerous fluids.

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3.7 Efficient use

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Apply correct and regular maintenance, according to these operating instructions.

Always use genuine GEHO spare parts and wear parts.

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3.8 Safety equipment

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3.8.1 Safety related documentation

@ 36725 3.8.1 Safety related documentation DANGER If applicable, than refer to the book "MANUF

DANGER

If applicable, than 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: 5.20 /GEHO/Safety/Product Safety/### DANGER: CE conformity @ 4\mod_1214979575442_31.doc @ 36701

3.8.2 CE conformity

@ 4\mod_1214979575442_31.doc @ 36701 3.8.2 CE conformity DANGER If failing to install and maintain the SAFETY

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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SAFETY

SAFETY

3.8.3 Emergency stop button

Pos: 5.22 /GEHO/Safety/Product Safety/DANGER: emergency button @ 4\mod_1214979911686_31.doc @ 36709

CE conformity

button @ 4\mod_1214979911686_31.doc @ 36709 CE conformity Pos: 5.23 /GEHO/Safety/Product Safety/Emergency stop button

Pos: 5.23 /GEHO/Safety/Product Safety/Emergency stop button @ 0\mod_1137483963358_31.doc @ 1243

DANGER

If failing to install and maintain the EMERGENCY 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:

"

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

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

According to local regulations an emergency stop button must be provided by the customer.

It is mandatory to install an EMERGENCY STOP button within a short range of the pump 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.

button is the customer, as stated in the written contract. Pos: 5.24 /GEHO/Heading/H3/#.#.# Safety covers and

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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.

3.8.4 Safety covers and safety guards

Pos: 5.25 /GEHO/Safety/Product Safety/### Safety covers and safety guards @ 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.

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Technical data

Technical data

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4 Technical data

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4.1 Project information

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WEIR Project information

WEIR Project name

WEIR Project number

Customer purchase order number

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4.2 Customer information

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Customer information

Name

Address

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4.3 Manufacturer information

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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

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

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(+31) 77-3824844: R. Reijnders

Technical data

Technical data

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4.4 Technical data

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4.4.1 Operating characteristics

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Operation characteristics

 

Location of the equipment

Underground

Site elevation

990 meter underground

Liquid to be pumped

Liquid, dirty mine water max. 5% solids < 2mm

Minimum slurry temperature

Not available

Operating slurry temperature

Not available

Maximum slurry temperature

 

50°C

Specific slurry gravity

1.05 [ - ]

Maximum solid diameter

2

mm

Solid concentration, normal

 

150%

Solid concentration, maximum

 

5%

Maximum viscosity

Not available

pH value

6

- 8.5

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Technical data

Technical data

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4.4.2 Pump and project data

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Refer for details also to:

- Chapter "Instruments and drawings": 814.201189.00 "Dimensioned outline drawing".

- Chapter "Instruments and drawings": 814.201189.02 "Instrument and equipment list".

- Chapter "Electrical information".

- Chapter "Catalogue information".

GEHO pump 7201189/1

 

Pump No. see GEHO PUMPS identification plate

7201189/1

Pump Type see GEHO PUMPS identification plate

TZPM 1200

Capacity see GEHO PUMPS identification plate

Minimum

108 m 3 /hour 216 m 3 /hour

Maximum

Stroke rate (stroke per minute of a piston) see GEHO PUMPS identification plate:

Minimum

36 spm

Maximum

72 spm

n (s/min)

 

Operating discharge pressure see GEHO PUMPS identification plate

Rated

14 000 kPa 14 000 kPa

Maximum

Required power see GEHO PUMPS identification plate

Maximum

884 kW

Pump power end ratio

direct drive

Piston diameter

240 mm

Piston rod diameter

not applicable

Stroke

406.4 mm

Diaphragm size

26.5 liter

Valve size

API 11

Suction pulsation dampener, size

1 x 75/64 (liter/bar) bladder type

Discharge pulsation dampener, size

1 x 75/160 (liter/bar) bladder type

Pos: 8.14 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Technical data

Technical data

Pos: 8.15 /GEHO/Heading/H4/Connection - Electrical @ 0\mod_1133446672849_31.doc @ 306

4.4.2.1 Electrical connection

Pos: 8.16 /GEHO/Technical data sheets/Voltage/Australia 6600/50/3 - 415/50/3 - 24/DC @ 5\mod_1225985403284_31.doc @ 40203

Item

Voltage [V]

Frequency [Hz]

Phases

Main motor

6600

50

3

Auxiliary motors

415

50

3

Control panel HMI

Pos: 8.17 /GEHO/Heading/H4/Pump drive @ 0\mod_1133448795551_31.doc @ 321

24V

DC

 

4.4.2.2 Pump drive

Pos: 8.18 /GEHO/Technical data sheets/Main E-motor/TECO - AELN-WT001 @ 5\mod_1225985733972_31.doc @ 40211

Main E-motor

Manufacturer

Type / size

Voltage

Refer to "Appendix: Catalog"

Teco

AELN-WT001

6600 V – 50 Hz – 3 Phases

Pos: 8.19 /GEHO/Technical data sheets/Frequency converter/Customer supplied @ 0\mod_1137065501172_31.doc @ 1138

Frequency converter

 

Manufacturer

Customer supplied

Type

n/a

Pos: 8.20 /GEHO/Technical data sheets/Gearbox/Flender - B3SH 18-3 @ 5\mod_1225986096752_31.doc @ 40221

Gearbox

814.201189.31

Manufacturer

Flender

Type

B3SH 18-3

Power rating max.

884 kW

Input speed

146.5 – 1465 rpm

Output speed

7.2 – 72 rpm

Gearbox ratio

20.348

Gear cooling

Pos: 8.21 /GEHO/Heading/H4/Shaft coupling @ 0\mod_1133540284412_31.doc @ 341

External oil-to-air heat exchanger

4.4.2.3 Shaft couplings

Pos: 8.22 /GEHO/Technical data sheets/Shaft coupling/Flender - RUPEX RWN 450 @ 5\mod_1226319163120_31.doc @ 40337

E-motor / Gearbox

Manufacturer

Type

Refer to "Catalogue information" for details.

Flender

RUPEX RWN 450

Pos: 8.23 /GEHO/Technical data sheets/Shaft coup ling/Flender - ZAPEX ZW N 545A @ 0\mod_1133540782858_31.doc @ 346

Pump shaft / Gearbox

Manufacturer

Type

Refer to "Catalogue information" for details.

Flender

ZAPEX ZWN 545A

Pos: 8.24 /GEHO/Heading/H2/#.# Tightening torques @ 0\mod_1133269909891_31.doc @ 183

Technical data

Technical data

4.5 Tightening torques

Pos: 8.25.1 /GEHO/Heading/H3/#.#.# General torques @ 0\mod_1133270125801_31.doc @ 190

4.5.1 General torques

Pos: 8.25.2 /GEHO/Technical data sheets/General torques/General torques - grade 8.8 Nm @ 0\mod_1133862945227_31.doc @ 392

General = grade 8.8

Size

Torque [Nm]

Size

Torque [Nm]

M8

20

M33

1930

M10

50

M36

2470

M12

85

M39

3200

M16

210

M42

3900

M20

400

M45

4900

M24

700

M48

5900

M27

1040

M52

7600

M30

1410

M56

9400

Pos: 8.26.1 /GEHO/Heading/H3/#.#.# Foundation bolt torques according to DIN 529 @ 0\mod_1133863490701_31.doc @ 397

 

4.5.2

Foundation bolt torques according to DIN 529

 

Pos: 8.26.2 /GEHO/Technical data sheets/General torques/Foundation bolt torques - grade 3.6 Nm @ 0\mod_1133863255313_31.doc @ 395

 

General = grade 3.6

Size

Torque [Nm]

Size

Torque [Nm]

M20

110

M30

380

M24

190

M33

520

M27

280

M36

660

Pos: 8.27.1 /GEHO/Heading/H3/#.#.# Special torques @ 0\mod_1133270014401_31.doc @ 187

4.5.3

Special torques

 

Pos: 8.27.2 /GEHO/Technical data sheets/Special torques/Discharge valve unit/H.831.020.358 @ 3\mod_1196337642082_31.doc @ 19844

 

Discharge valve unit - 831.020.358

 

Pos: 8.27.3 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.005.001 - Discharge @ 5\mod_1226320766581_31.doc @ 40345

 

A.807.005.001 - Discharge

Part list ID

Torque [Nm]

Pressure [kPa]

Valve ring lock nut

 

013

300

 

Valve cover nut

       
 

1. step tightening

019

hand tight

1x 10 000

 

2. step tightening

019

hand tight

2x 60 000

 

3. step tightening

019

200 - 400

3x 115 000

Clamping piece screw

041

80

 

Screw Spacer / Valve cover

046

80

 

Nut valve housing / Discharge line

051

1200

 

Adapter / Connecting nipple

027 / 026

50

 

Assembly adapter and nipple / Valve housing

(027,026) / 001

50

 

Pos: 8.27.4 /GEHO/Technical data sheets/Special torques/Suction valve unit/H.831.020.359 @ 3\mod_1196341283886_31.doc @ 19856

Technical data

Technical data

Suction valve unit - 831.020.359

Pos: 8.27.5 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.005.000 - Suction @ 5\mod_1226561554715_31.doc @ 43682

A.807.005.000 - Suction

 

Part list ID

Torque [Nm]

 

Pressure [kPa]

Valve ring lock nut

 

013

300

 

Valve cover nut

 

019

200 - 400

115 000

Nut valve housing / Suction line

       
 

1. step tightening

044

1200

 
 

2. step tightening

044

2400

 
 

3. step tightening

044

3700

 

Adapter / Connecting nipple

 

027 / 026

50

 

Assembly adapter and nipple / Valve housing

 

(027,026) / 001

50

 

Pos: 8.27.6 /GEHO/Technical data sheets/Special torques/Diaphragm housing unit/H.832.010.123-M33 @ 2\mod_1178895354267_31.doc @ 13654

 

Diaphragm housing unit - 832.010.123-M33

 

Pos: 8.27.7 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.886+A.807.004.771 hydr.diap.house @ 0\mod_1138890120655_31.doc @ 2327

 

A.807.004.886

Part list ID

Torque [Nm]

 

Pressure [kPa]

Monitoring rod / diaphragm

015

/ 019

140

 

Diaphragm housing screw

038

= M33

1500

 

Power end connection nut

040, 044

1965

 

A.807.004.771

Part list ID

Torque [Nm]

 

Pressure [kPa]

Use special tool:

 

Use special tool:

 

Use hydraulic pump

Hydraulic tension unit

pin 013 for cover nut.

Diaphragm housing cover nut

045

   

1.

Tighten

045

   

1.1. Pre-tighten

045

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

125

000 pre-tighten.

1.2. Relieve for settling of parts

045

 

Relieve oil pressure.

1.3. Final-tighten

045

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

125

000 final-tighten.

2.

Loosening

045

Loosening cover nut with pin by hand.

125

000

Pos: 8.27.8 /GEHO/Technical data sheets/Special torques/Piston unit/H.835.093.204 @ 3\mod_1205919947109_31.doc @ 27523

 

Piston unit - 835.093.204

Pos: 8.27.9 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.963 Piston unit @ 3\mod_1205941932311_31.doc @ 27576

A.807.004.963 - Piston unit

 

Part list ID

Torque [Nm]

 

Pressure [kPa]

Piston unit lock nut

 

006

750

 

Piston body lock nut

Pos: 8.27.10 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/H.851.010.115 @ 2\mod_1188801674043_31.doc @ 14987

 

010

1000

 

Technical data

Technical data

Pulsation damper unit - 851.010.115

Pos: 8.27.11 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.894=75/160 puls.damp. @ 2\mod_1188801803467_31.doc @ 14992

A.807.004.894

Part list ID

Torque [Nm]

Pressure [kPa]

Pulsation damper flange screw

013

1060

 

Pulsation damper cover nut

014

2800

 

Pos: 8.27.12 /GEHO/Technical data sheets/Special torques/Pressure limitation regulation unit/H.853.010.251 @ 2\mod_1193298411076_31.doc @ 18740

     

Pressure limitation regulation unit - 853.010.251

Pos: 8.27.13 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.883 @ 2\mod_1181215948540_31.doc @ 13907

A.807.004.883

Part list ID

Torque [Nm]

Pressure [kPa]

Nut Safety valve / Drain line

010

350

 

Pos: 8.27.14 /GEHO/Technical data sheets/Special torques/Pulsation damper unit/H.851.010.092 @ 2\mod_1188563881248_31.doc @ 14905

Pulsation damper unit - 851.010.094

Pos: 8.27.15 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.650-851.010.092=75/64 puls.damp. @ 3\mod_1204642384820_31.doc @ 27032

A.807.004.650

Part list ID

Torque [Nm]

Pressure [kPa]

Pulsation damper cover nut

Pos: 8.27.16 /GEHO/Technical data sheets/Special torques/Special tools/H.897.010.710 @ 3\mod_1197678887995_31.doc @ 24914

014

1290

 

Special tool: Hydraulic pump unit - 897.010.710

Pos: 8.27.17 /GEHO/Technical data sheets/Special torques/A-Specification/A.807.004.622 Hydr.pump-imp @ 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:

002

/ 004

 

Non

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").

Pos: 8.28 /GEHO/Heading/H2/#.# Auxiliary connections and Lubrication data @ 0\mod_1137667733207_31.doc @ 1351

 

4.6 Auxiliary connections and lubrication data

Pos: 8.29 /GEHO/Technical data sheets/Refer to Utility consumption list @ 0\mod_1148974052988_31.doc @ 4381

Refer to the “Utility consumption list” for more information about auxiliary connections and lubrication data.

Pos: 8.30 /GEHO/Heading/H2/#.# Drawings+Lists+Instruments @ 0\mod_1133876951146_31.doc @ 421

Technical data

Technical data

4.7 Drawings + lists + instruments

Pos: 8.31 /GEHO/Technical data sheets/Project/201189/Instrument and drawings @ 5\mod_1225113511579_31.doc @ 39834

Drawings and lists

 

Dimensioned outline drawing

814.201189.00

Foundation drawing

814.201189.01

Instrument and equipment list

814.201189.02

P & I diagram

814.201189.03

Pump Data Sheet

PDS.201189

Packing unit

V.814.201189.15

Utility consumption list

814.201189.19

Description of Pump Control System

814.201189.20

Typical Manual of the GEHO Touch Panel

814.200000.22

Flushing/Filling/Drain Connections

Pos: 9 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

814.200000.04

Description

Description

Pos: 10.1 /GEHO/Heading/H1/#. Description @ 0\mod_1134483846926_31.doc @ 448

5

Pos: 10.2.1 /GEHO/Heading/H2/#.# Introduction @ 0\mod_1144834888602_31.doc @ 3092

5.1

Description

Introduction

Pos: 10.2.2 /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: 10.2.3 /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.

Pos: 10.2.4 /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: 10.2.5 /GEHO/Heading/H4/Wearing parts @ 0\mod_1134635462418_31.doc @ 560

5.1.1.1 Wearing parts

Pos: 10.2.6 /GEHO/Description/Introduction/Wearing parts: Definition @ 0\mod_1134639095462_31.doc @ 580

Wearing parts are parts subject to exchange regularly.

Pos: 10.2.7 /GEHO/Description/Introduction/Wearing parts: List @ 0\mod_1134635624621_31.doc @ 570

These are:

Suction valve

Discharge valve

Pos: 10.2.8 /GEHO/Heading/H4/Replacement parts @ 0\mod_1134635502866_31.doc @ 564

5.1.1.2 Replacement parts

Pos: 10.2.9 /GEHO/Description/Introduction/Replacement parts: Definition @ 0\mod_1134639331822_31.doc @ 582

Replacement parts are parts subject to be replaced, if required.

Pos: 10.2.10 /GEHO/Description/Introduction/Replacement parts: List @ 0\mod_1134635786604_31.doc @ 572

These are:

Pump diaphragm

Pulsation dampener diaphragm

Pos: 10.2.11 /GEHO/Heading/H4/Non-wearing parts @ 0\mod_1134635392998_31.doc @ 555

5.1.1.3 Non-wearing parts

Pos: 10.2.12 /GEHO/Description/Introduction/TZPM/Non-wearing parts @ 0\mod_1134634939436_31.doc @ 554

Piston

Piston rod

Piston seal rings

Cylinder liner

Pos: 10.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Description

Description

Pos: 10.4.1 /GEHO/Heading/H2/#.# Working principle @ 0\mod_1135000311087_31.doc @ 611

5.2 Working principle

Pos: 10.4.2 /GEHO/Description/Working principle/TZPM/TZPM general @ 2\mod_1176882885858_31.doc @ 13241

The GEHO TZPM pump is a single acting pump with 3 cylinders and 3 pistons. Each single acting piston uses propelling liquid to drive a diaphragm, which pumps the slurry. This enables low-wear components to be used and to pump a solids containing liquid or slurry at high pressure.

1 Pump crank shaft drives 3 single acting pistons, driving in total 3 diaphragms. With every revolution of the pump crank shaft, each piston makes 1 suction stroke and 1 discharge stroke, so the pump makes in total 3 diaphragm suction strokes and 3 diaphragm discharge strokes.

Pos: 10.4.3 /GEHO/Description/Working principle/TZPM/Suction stroke @ 0\mod_1134999056904_31.doc @ 606

5.2.1 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).

Pos: 10.4.4 /GEHO/Description/Working principle/TZPM/Discharge stroke @ 0\mod_1134999494473_31.doc @ 608

5.2.2 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).

Pos: 10.5 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

G F E C B A D
G
F
E
C
B
A
D
Figure 5.1: Working principle: Suction stroke H G F E C B A
Figure 5.1: Working principle: Suction stroke
H
G
F
E
C
B
A

Figure 5.2: Working principle: Discharge stroke

Description

Description

Pos: 10.6.1 /GEHO/Heading/H2/#.# Drive unit @ 0\mod_1134483988099_31.doc @ 452

5.3 Drive unit

Pos: 10.6.2 /GEHO/Description/Drive unit/Gearbox type @ 0\mod_1134639813244_31.doc @ 584

The main E-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 E-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: 10.7 /GEHO/Heading/H2/#.# Power end @ 0\mod_1134484023820_31.doc @ 454

5.4 Power end

Pos: 10.8 /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: 10.9 /GEHO/Description/Power end/Project/201189=TZPM 1200 @ 5\mod_1226500711865_31.doc @ 43622

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: 10.10.1 /GEHO/Heading/H3/#.#.# Lubrication unit @ 0\mod_1134568393543_31.doc @ 498

5.4.1 Lubrication unit

Pos: 10.10.2 /GEHO/Description/Power end/Lubrication unit/TZPM/Introduction @ 0\mod_1136372541764_31.doc @ 918

The lubrication unit supplies fresh oil to the bearings, the crosshead liners and the crosshead rod.

Pos: 10.11 /GEHO/Heading/H2/#.# Liquid end @ 0\mod_1134568182139_31.doc @ 492

5.5 Liquid end

Pos: 10.12.1 /GEHO/Description/Liquid end/Introduction/TZPM/Main items - TZPM - Header @ 0\mod_1145875032918_31.doc @ 3323

The TZPM pump consist of the following parts:

Pos: 10.12.2 /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: 10.12.3 /GEHO/Description/Liquid end/Introduction/Main items/ Pulsation dampener - Suction (1) @ 1\mod_1173099006839_31.doc @ 12590

1 Suction pulsation dampener.

Pos: 10.12.4 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (1) @ 0\mod_1135002171112_31.doc @ 623

1 Discharge pulsation dampener.

Pos: 10.12.5 /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.

Description

Description

Pos: 10.12.6 /GEHO/Description/Liquid end/Introduction/Propelling liquid section/TZPM @ 1\mod_1166113655949_31.doc @ 11322

5.5.1 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: 10.12.7 /GEHO/Description/Liquid end/Introduction/Slurry section/Standard @ 0\mod_1149662677848_31.doc @ 4423

5.5.2 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: 10.12.8 /GEHO/Description/Liquid end/Introduction/Main items/ Pulsation dampener - Suction (1) @ 1\mod_1173099006839_31.doc @ 12590

1 Suction pulsation dampener.

Pos: 10.12.9 /GEHO/Description/Liquid end/Introduction/Main items/Pulsation dampener - Discharge (1) @ 0\mod_1135002171112_31.doc @ 623

1 Discharge pulsation dampener.

Pos: 10.13.1 /GEHO/Heading/H3/#.#.# Piston unit @ 0\mod_1134569925466_31.doc @ 512

5.5.3 Piston unit

Pos: 10.13.2 /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: 10.13.3 /GEHO/Description/Liquid end/Piston unit/Piston @ 0\mod_1135242883584_31.doc @ 732

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

The piston guide ring centers the piston in the cylinder liner.

Pos: 10.13.4 /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: 10.13.5 /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: 10.13.6 /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: 10.14 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Description

Description

Pos: 10.15.1 /GEHO/Heading/H3/#.#.# Propelling liquid control system @ 0\mod_1134632211894_31.doc @ 522

5.5.4 Propelling liquid control system

Pos: 10.15.2 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM schematics @ 0\mod_1135261173624_31.doc @ 755

1 2 K 3 PLC 4 FILL 5 DRAIN J L I H G F
1
2
K
3
PLC
4
FILL
5
DRAIN
J
L
I
H
G
F
E
D
C
B
A

Figure 5.3: 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

J

Discharge valve

for limitation of the diaphragm stroke

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 FILL

= automatic filling of propelling liquid,

if the position marker (I) at the rod reaches the minimum-probe

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

Pos: 10.15.3 /GEHO/Description/Liquid end/Propelling liquid control system/TZPM/TZPM Propelling liquid control system @ 2\mod_1175168658938_31.doc @ 12922

The pump is standard equipped with a patented GEHO propelling liquid automatic control system:

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 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.

Description

Description

Possible causes for (slow, long term) change of the propelling liquid volume at a TZPM pump:

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.

Pos: 10.15.4 /GEHO/Description/Liquid end/Propelling liquid control system/Caution - Release remaining pressure @ 0\mod_1136282494105_31.doc @ 786

remaining pressure @ 0\mod_1136282494105_31.doc @ 786 CAUTION Before installation or service or maintenance work:

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

5.5.5 Flushing unit

Pos: 10.16.2 /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: 10.16.3 /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. In case of propelling liquid needs to be supplied to the propelling liquid section, 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: 10.17.1 /GEHO/Heading/H3/#.#.# Diaphragm housing unit @ 0\mod_1134569604134_31.doc @ 504

5.5.6 Diaphragm housing unit

Pos: 10.17.2 /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.

Description

Description

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: 10.17.3 /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: 10.18.1 /GEHO/Heading/H3/#.#.# Suction valve unit @ 0\mod_1134569502477_31.doc @ 502

5.5.7 Suction valve unit

Pos: 10.18.2 /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: 10.18.3 /GEHO/Heading/H3/#.#.# Discharge valve unit @ 0\mod_1137069603901_31.doc @ 1146

5.5.8 Discharge valve unit

Pos: 10.18.4 /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.

Pos: 10.19 /GEHO/Heading/H3/#.#.# Suction pulsation dampener @ 0\mod_1160051076345_31.doc @ 6400

5.5.9 Suction pulsation dampener

Pos: 10.20 /GEHO/Description/Liquid end/Pulsation dampener/Suction/Introduction @ 0\mod_1160050898959_31.doc @ 6394

The suction pulsation dampener minimizes the pressure variations in the suction line. This achieves a constant flow in the suction line.

A rubber diaphragm separates the pulsation dampener into 2 sections:

The slurry section.

The nitrogen section, pre-charged with nitrogen.

Pos: 10.21 /GEHO/Heading/H3/#.#.# Discharge pulsation dampener @ 0\mod_1134569676478_31.doc @ 506

5.5.10 Discharge pulsation dampener

Pos: 10.22 /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: 10.23 /GEHO/Heading/H4/Over pressure alarm @ 0\mod_1136289931970_31.doc @ 828

5.5.10.1 Over-pressure alarm

Pos: 10.24 /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: 10.25 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - Common @ 0\mod_1136289605881_31.doc @ 824

Description

Description

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.

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

Pos: 10.26.1 /GEHO/Heading/H3/#.#.# Pressure limitation system @ 0\mod_1134569743995_31.doc @ 508

5.5.11 Pressure limitation system

Pos: 10.26.2 /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 "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: 10.26.3.1 /GEHO/Heading/H4/Pressure limitation - Electrical @ 0\mod_1136292111124_31.doc @ 846

5.5.11.1 Electrical pressure limitation

Pos: 10.26.3.2 /GEHO/Description/Liquid end/Pressure transmitter/Pressure transmitter - Common @ 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.

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

Pos: 10.26.4.1 /GEHO/Heading/H4/Pressure limitation - Mechanical @ 0\mod_1136292155037_31.doc @ 848

5.5.11.2 Mechanical pressure limitation

Pos: 10.26.4.2 /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: 10.26.4.3 /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: 10.26.4.4 /GEHO/Description/Liquid end/Pressure limitation system/Caution - Release pressure @ 0\mod_1136295053785_31.doc @ 858

- Release pressure @ 0\mod_1136295053785_31.doc @ 858 CAUTION Before installation or service or maintenance work:

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.

Pos: 10.27.1 /GEHO/Heading/H2/#.# Pump control system @ 0\mod_1134569924544_31.doc @ 510

Description

Description

5.6 Pump control system

Pos: 10.27.2 /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:

A PLC (Programmable Logic Controller).

The HMI (Human Machine Interface).

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 PLC/HMI 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: 11 /--- Section break - Odd page --- @ 0\mod_1136277036628_0.doc @ 765

Description

Description

Transport and installation

Transport and installation

Pos: 12.1 /GEHO/Heading/H1/#. Transport and installation @ 0\mod_1136455268304_31.doc @ 931

6 Transport and installation

Pos: 12.2.1.1 /GEHO/Heading/H2/#.# Transport and lifting @ 0\mod_1136806045785_31.doc @ 973

6.1 Transport and lifting

Pos: 12.2.1.2 /GEHO/General/Attention, Warning and Note/DANGER - Safety - Obey safety instructions and procedures @ 0\mod_1136886637385_31.doc @ 1007

and procedures @ 0\mod_1136886637385_31.doc @ 1007 DANGER • Obey the safety instructions. • Obey the

DANGER

Obey the safety instructions.

Obey the working procedures.

Pos: 12.2.1.3 /GEHO/General/Attention, Warning and Note/Caution - Lifting device - Check for damage @ 0\mod_1136886348800_31.doc @ 1005

- Check for damage @ 0\mod_1136886348800_31.doc @ 1005 CAUTION • Check the lifting devices for damage

CAUTION

Check the lifting devices for damage before use.

Replace damaged parts immediately.

Pos: 12.2.1.4 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Weight limits @ 0\mod_1136885967642_31.doc @ 1003

devices - Weight limits @ 0\mod_1136885967642_31.doc @ 1003 ATTENTION • Make sure to use only lifting

ATTENTION

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

Pos: 12.2.1.5 /GEHO/General/Attention, Warning and Note/Attention - Lifting devices - Protect equipment @ 0\mod_1136886849861_31.doc @ 1009

- Protect equipment @ 0\mod_1136886849861_31.doc @ 1009 ATTENTION • Make sure to protect the equipment when

ATTENTION

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

Pos: 12.2.1.6 /GEHO/General/Attention, Warning and Note/Attention - Lifting locations - Use lifting eyes or flanges @ 0\mod_1136885672808_31.doc @ 1001

lifting eyes or flanges @ 0\mod_1136885672808_31.doc @ 1001 ATTENTION • Make sure to use the provided

ATTENTION

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

Pos: 12.2.1.7 /GEHO/Heading/H3/#.#.# Weights and limits @ 0\mod_1137424754577_31.doc @ 1233

6.1.1 Weights and weight limits

Pos: 12.2.1.8 /GEHO/Transport and installation/Transport and lifting/Caution - Weight limits @ 0\mod_1137425074277_31.doc @ 1237

- Weight limits @ 0\mod_1137425074277_31.doc @ 1237 CAUTION • Never exceed the weight limits. • Use

CAUTION

Never exceed the weight limits.

Use the correct transport and lifting gear.

Pos: 12.2.1.9 /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: 12.2.2 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Transport and installation

Transport and installation

Pos: 12.2.3.1 /GEHO/Heading/H3/#.#.# Transport the packed installation @ 0\mod_1137408313966_31.doc @ 1177

6.1.2 Transport the packed installation

Pos: 12.2.3.2 /GEHO/Transport and installation/Transport and lifting/Transport/Transport box @ 0\mod_1137408396926_31.doc @ 1182

box @ 0\mod_1137408396926_31.doc @ 1182 WARNING • Obey the instructions at the transport box. •

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.

Pos: 12.2.4 /GEHO/Heading/H3/#.#.# Pump @ 0\mod_1137414488876_31.doc @ 1207

6.1.3

Pump

Pos: 12.2.5 /GEHO/Transport and installation/Transport and lifting/Lifting locations/TZPM/Standard, pump+liq.end, refer to special tools @ 1\mod_1173178868349_31.doc @ 12620

The power end and liquid end are shipped preassembled.

Refer to chapter "Technical data sheets":

drawing "Packing drawing".

Make sure to use the transport support.

Lift the pump at the four lifting points or flanges.

Pos: 12.2.6 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

12.2.6 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766 Figure 6.1: Lifting locations at the transport

Figure 6.1: Lifting locations at the transport box

Hoisting unit Refer to the drawing in chapter “Part lists and drawings (special tools)”.

Transport and installation

Transport and installation

Pos: 12.2.7.1 /GEHO/Heading/H3/#.#.# Drive unit @ 0\mod_1136807338183_31.doc @ 987

6.1.4 Drive unit

Pos: 12.2.7.2 /GEHO/Transport and installation/Transport and lifting/Lifting locations/Drive Unit/Drive unit-no-motor+gearbox+1hoistspreaders$01 @ 2\mod_1188825775979_31.doc @ 15122

6.1.5 Drive unit frame

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 Dis-assemble the gearbox from the frame.

2 Hoist separately the gearbox and the frame at their hoisting points.

Pos: 12.2.8.1 /GEHO/Heading/H3/#.#.# Smaller parts @ 0\mod_1136807299788_31.doc @ 985

6.1.6 Smaller parts

Pos: 12.2.8.2 /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.

A B1 B2 B4 B3
A
B1
B2
B4
B3

C

Figure 6.2: Lifting locations at the drive unit frame

Error! Unknown switch argument. Pos: 12.2.9 /GEHO/General/Attention, Warning and Note/Warning - Lifting locations @ 0\mod_1137404858107_31.doc @ 1159

- Lifting locations @ 0\mod_1137404858107_31.doc @ 1159 WARNING • Refer to chapter "Special tools", the

WARNING

Refer to chapter "Special tools", the drawing “Lifting tools” for the exact lifting locations, lifting values and restrictions.

Pos: 12.3 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Transport and installation

Transport and installation

Pos: 12.4 /GEHO/Heading/H2/#.# Installation @ 0\mod_1136888682286_31.doc @ 1015

6.2

Pos: 12.5.1 /GEHO/Heading/H3/#.#.# Foundation @ 0\mod_1136888827835_31.doc @ 1021

6.2.1

Installation

Foundation

Pos: 12.5.2 /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 Foundation bolt hook

D C B A I E J H G F
D
C
B
A
I
E
J
H
G
F

Figure 6.3: Schematics of the anchor pocket and the foundation bolt

Pos: 12.5.3 /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 or the “Foundation drawing” for the exact sizes and locations of the anchor pockets.

Pos: 12.5.4 /--- Page break --- @ 0\mod_1136278659331_0.doc @ 766

Transport and installation

Transport and installation

Pos: 12.5.5.1 /GEHO/Heading/H4/#.#.# Mount and level the pump @ 0\mod_1136965605812_31.doc @ 1041

6.2.2 Mount and level the pump

Pos: 12.5.5.2 /GEHO/Transport and installation/Installation/Foundation/Mount and level/TZPM/Level - TZPM @ 0\mod_1137418638092_31.doc @ 1214

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 Put the thread of the foundation bolts into the borings at the pump.

6 Put the nuts to the foundation bolts.

7 Lower the pump

8 Put the pump to the steel blocks.

9 Make sure that the foundation bolts fit into the anchor pockets.
10 Hook the foundation bolts in their dedicated position.
11 Tighten the nuts at the foundation bolts by hand.
12 Place exactly below all leveling bolts of the pump a plane steel block. Use steel blocks with a thickness of about 40 mm. ATTENTION Avoid that any pollution does enter the inside of the pump, during the time that a below mentioned frame cover are removed from the pump.

a below mentioned frame cover are removed from the pump. 13 Remove 1 cover of a

13 Remove 1 cover of a piston cover and crosshead chamber. See the figure beside.

14 Place a spirit level (C) on the machined face in direction A-A.

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