Slurry Pump: Learner Guide

Field Operator Certification
Slurry Pump
Learner Guide
Introduction
This lesson on Slurry Pumps, as with your other lessons on Auxiliary Equipment, consists of two
main learning components a self-directed/in-class component and an on-the-job component. You
are expected to complete both components as part of your Certification Program.
Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.
Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.
Self-Directed/In Class Learning Objectives

State the purpose for Slurry Pumps
Name the main components of Slurry Pumps
Describe the principle of operation for Slurry Pumps
Describe the types of drives used for Slurry Pumps
State the applications for Slurry Pumps in the cement manufacturing process
Describe the troubleshooting methodology used for a loss of pump capacity
Describe the inspection points for a Slurry Pump
Identify safety concerns associated with the operations of Slurry Pumps
On-The-Job Learning Objectives

Perform an inspection on an operational Slurry Pump
Perform an inspection on a static Slurry Pump
Field Operator Certification 2/10/2017 1

Slurry Pumps Learner Guide
Lesson Outline
The first portion of this lesson, the self-directed/in-class portion, involves reviewing the following
information:
The purpose and basic principle of operation of a Slurry Pump, including different types of
Pumps
A listing and description of the various components of a Slurry Pump
Various applications of a Slurry Pump
Safety concerns related to Slurry Pumps
Pictures and graphics are included where appropriate to help you understand how a Slurry Pump
functions. At the end of this section, there are a series of questions that you will be required to
answer and review with your Instructor.
The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Slurry Pumps, including both an operational and static Slurry Pump
inspection and lockout procedures. When you are ready to perform these inspections, inform your
Instructor.
If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.
Step One
Your Instructor will walk through an inspection procedure with you. At that time
you can ask questions and take down any notes required.
This walk-through may be completed out in the field or during a meeting with your
Instructor.
Step Two
Your Instructor will demonstrate an inspection procedure in the field.
Step Three
You will conduct an inspection procedure in the field under the supervision of your
Instructor.
Your Instructor will provide you with feedback about your performance during the
inspection.
Step Four
2 2/10/2017 Slurry Pump Learner Guide

You will complete a full inspection procedure without any assistance from your
Instructor.
This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with
inspection procedures. Discuss this with your Instructor and you may only be required to
actually complete Step Four as discussed above.
Reference Material
NA
Pre-requisites
The following Auxiliary Equipment Module
Fans

Slurry Pumps Learning Content

Purpose
Unique Pump designed to transfer abrasive slurries efficiently and reliably
Specific to Raw Grinding and Kiln Feeding systems in wet process cement manufacturing
Components
Pump Casing
Case Liner
Runner/Impeller
Follower/Expeller
Pump Seals
Intake Chamber
Discharge Chamber
Support Bearing Assembly
Drive System
S LURRY P UMP

Principle of Operation
Slurry Pumps operate under much the
same principle as a Centrifugal Fan
Slurry enters the Pump through the
intake pipe and is accelerated through
casing by centrifugal force
The centrifugal force is imparted on
the slurry by the impeller or runner
which is rotated within the casing by
the energy applied at the drive
The slurry is then expelled out of the
Pump through the discharge pipe
As material is expelled from the Pump, a low pressure is created at the Pump intake in
relation to atmospheric pressure which, in turn, forces more slurry into the Pump casing
In some applications, fresh water is pumped around a packed seal between the casing and the
impeller shaft to protect the seals and bearings from the abrasive slurry
The fresh water in these seals is maintained at a higher pressure than the slurry casing
pressure to prevent leakage past the seals
Slurry Pump Drives

Direct Drive
The Pump is directly coupled
to a constant speed motor
Belt Drive
The Pump is drive at a
constant speed through a
combination of sheaves and belts
Variable Speed
The Pump is either coupled
directly or through sheaves and belt to a variable speed drive DC or VFD Control
Control
Slurry Pumps are controlled by a simple PID loop to maintain constant level or flow by
controlling the speed of the Pump (VFD) or, in the case of a constant speed Pump, by
controlling external value positions to divert excess slurry when necessary

Applications
Kiln Feed
Re-circulation
Transporting product

Inspection Points
Slurry Pump Running Inspection

Check For OK
Inspect the Slurry Pump drive motor for material build-up on cooling fins and cooling fan inlet screen.
Remove build-up
Inspect drive motor electrical connections for damage or strain
Inspect the condition and support of integrity of all safety guards
Verify the Slurry Pumps direction of rotation
Palm test the motor casing temperature; if too hot to touch, record temperature with hand pyrometer or
contact thermometer
Inspect the general condition of the equipment cleanliness, damage
Inspect the condition of the final drive V-belt condition, tensioning, sheaves, direct coupling
Inspect the pump and drives mounting base for damage, cracks, loose bolts
Palm test Slurry Pump bearing temperatures; if too hot to touch, record temperature with hand pyrometer
or contact thermometer
Listen for abnormal noise or vibration in the Slurry Pump or drive system
Inspect field control station for damage or cable strain. Remove any obstructions for access
Inspect discharge piping and flanges for leaks
Inspect Slurry Pump casing for wear or leaking slurry

Slurry Pump Static Inspection

Check For OK
Inspect the Slurry Pump drive motor for material build-up on cooling fins and cooling fan inlet screen.
Remove Build-up
Inspect drive motor electrical connections for damage or strain
Inspect the condition and support integrity of all safety guards
Inspect the Slurry Pump impeller, follower, for build-up, corrosion, excessive wear
Inspect the Slurry Pump and drives mounting base for damage, cracks, loose bolts
Inspect Slurry Pump casing for wear, damage or signs of in-leakage to seals
Inspect the condition of the drive belts, check tensioning, sheaves, or drive coupling
Verify the Slurry Pumps direction of rotation
Inspect the general condition of the equipment cleanliness, damage
Inspect field control station for damage or cable strain. Remove any obstructions for access

Troubleshooting
Pump System Troubleshooting

Problem Test Test Results Indicates Action to Take
No flow or low flow 1. Remove belts; rotate Shaft rotates freely Proceed to No. 2
motor shaft by hand
Shaft wont turn, or Motor malfunction Repair or replace motor
rubbing noise
3. Rotate pump shaft by Shaft rotates freely Proceed to No. 3
hand
Pump shaft wont turn Pump malfunction Check adjustment of runner
and follower plate gap. If
gap is adjusted correctly,
disassemble pump to
determine malfunction
4. Start motor; check Rotation correct Proceed to No. 4
direction of rotation
Rotation incorrect Motor wiring reversed Correct motor electrical
connections
5. Check pump shaft speed Pump speed correct Proceed to No. 6
Pump speed incorrect Proceed to No. 5
6. If pump gearbox or V- Motor speed correct
Belt driven, check motor
Motor speed incorrect Sheaves or gear ratio Correct speed ratio
speed
wrong Correct as required
Wrong motor or low
voltage
8. While pump is not Inlet pressure correct Proceed to No. 7
running, install pressure Inlet pressure low or Inlet valve closed or Open valve or free
gauges at pipe inlet and
missing blocked blockage
discharge
Proceed to No. 7
Slurry Pump Learner Guide 2/10/2017 9


No flow or low flow 9. Start pump and motor; Inlet pressure correct Proceed to No. 8
(contd) check inlet pressure
No inlet pressure Unit cavitating or not Bleed pump case
primed Check valves and piping
Low inlet pressure Inlet line restricted or air

Use defoamer, eliminate air
leaks in inlet piping,
leaks or install vent pipe for
excessive vapors (low
froth.
NPSH), foaming of fluid
Correct HPSH problems
11. Check discharge Pressure at pump correct
pressure and compare Pressure higher than Faulty instrumentation Proceed to No. 9
with head-flow curve
normal Discharge valve or piping Correct blockage
blocked
Pressure lower than normal Excessive runner Adjust runner to follower

clearance, runner or plate gap
follower plate damage
(could indicate excessive Repair worn or damaged
pump flow and delivery; parts
proceed to No. 9)
13. Check flow Measurements do not Instrumentation error Check valving,
instrumentation vs. correspond instrumentation and piping
physical measurement


Noise and/or vibration 1. Visually check for loose Bolts and screw secure Proceed to No. 2
or missing screws or Loose or missing bolts Improper or incomplete Replace and tighten bolts
bolts from coupling or
assembly
tie-down points
3. Inspect belts and sheave Belts and sheaves OK Proceed to No. 3
for balance and Belt and sheave out of Poor alignment and Adjust or replace as needed
alignment
balance or alignment balance
5. Rotate pump by hand Pump free and clear Proceed to No. 4
Scraping, clunking or other Proceed to No. 5
unusual noise heard or
pump wont turn freely and
easily
7. With unit running, Grinding, scraping, Runner rubbing on Adjust runner to follower
monitor type and rubbing noise heard from follower plate plate gap
location of noise. Use pump only
stethoscope or Scraping or rubbing noise
screwdriver held against Possibly motor fan blades Consult motor manual
hear from motor only loose or bent
pump and motor housing Proceed to No. 5
over bearings Thumping or clicking Bearings malfunction
noise or excessive
vibration
8. Push and pull pump and No shaft movement Bearing OK Proceed to No. 6
motor shafts in both observed
radial and axial Shaft wiggles or moves Failed bearings Replace bearings
directions
10. With belts removed, turn Motor quiet Recheck tests
on motor and listen for Noisy Motor failure Remove and replace
noise


Motor runs hot or 1. With motor and pump Shaft turns freely, no noise Proceed to No. 2
throws breaker not running, verify by
Shaft drag or noise Mechanical problem Go to Noise and/or
hand that unit rotates
Vibration section, No. 1
freely without noise or
drag
3. Check breaker fuse size Breaker fuse and motor Correct fuse and motor Proceed to No. 3
and motor nameplate rating correspond
rating
Breaker fuse and motor do Incorrect fuse Install proper fuse
not correspond
4. With motor and pump Speed and motor direction Correct motor and Proceed to No. 4
running, check pump OK frequency
and motor speed
Speed of pump wrong Incorrect motor or Correct motor
frequency
5. Measure pump output Flow and pressure correct Proceed to No. 5
flow rate and/or
Flow too high (discharge Improper valving or Correct system problems
discharge pressure
pressure low) system upset
6. Measure motor Amperage (HP) OK Proceed to No. 6
amperage or HP
Amperage (HP) too high Mechanical failure of Go to Noise and/or
pump or motor Vibration section, No. 1
Motor runs hot or 7. Measure motor and Motor voltage OK Proceed to No. 7
throws breaker voltage at motor and
Motor voltage low Incorrect voltage Correct voltage
breaker
(contd)
9. Check motor fan cooling Good air flow, cool Motor problem Consult motor manual
and air flow temperature
No air flow Motor problem Consult motor manual
Motor fan difficult or Improve air flow, consult


shroud blocked motor manual

Whenever leakage is encountered, before removing pump, visually determine when the leakage is occurring (i.e., either while pump is running
or when pump is at full stop). Once you have determined when the pump is leaking, following the guide below.
Visually determine exact Leakage from diaphragm Pump inlet pressure exceeds Check inlet pressure
Leakage leakage point area expeller capacity
normal running
Tighten gland ring or replace
Gland ring loose packing
Excessive wear on expeller

or die ring wear
Disassemble pump and check
expeller and front & rear die
rings for wear. Expeller vanes
should not be clogged or
caked with material. Rear die
ring face should be free of
wear. Front die ring lip
Leakage from case or gasket Damaged seal surface, gasket should be free of wear
area failure or loose bolts
Check tightness of case bolts.

See that the case plate fits
tightly and is in good
condition. If leakage
continues, disassemble pump
and inspect gasket sealing
surfaces and gasket. Replace
worn or damaged parts
Visually determine exact Leakage from diaphragm Problem with diaphragm or Thoroughly wash
Leakage leakage point area shaft sleeve diaphragm area with clean
at complete stop water. Accomplish this

Whenever leakage is encountered, before removing pump, visually determine when the leakage is occurring (i.e., either while pump is running
or when pump is at full stop). Once you have determined when the pump is leaking, following the guide below.
without disassembling the
pump, by spraying the
diaphragm with a hose. If
leakage persists,
disassemble pump and
replace worn diaphragm or
shaft sleeve
Tighten gland ring or replace

Gland ring loose packing
Check tightness of case bolts.

Leakage from case or gasket Damaged seal surface, gasket See that the case plate fits
area failure or loose bolts tightly and is in good
condition. If leakage
continues, disassemble
pump and inspect gasket
sealing surfaces and
gasket. Replace worn or
damaged parts

Safety Work Page
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Slurry Pump Learner Guide
Safety
Follow lock-out procedure before performing work on Slurry Pumps
Be aware that this equipment is controlled automatically and can start and stop at any time
Slurry Pumps operate under positive air pressure. Ensure that pressure is released prior to
performing work on any component that could potentially be pressurized
Be aware that machine surface temperatures may pose a burn hazard
Ensure all guards are securely in place prior to starting. Immediately report any defective or
missing guards and tape off the area for restricted access
Know the location and function of all control stations
Keep all controls stations free from obstructions to ensure access at all times
Do not run a Pump with the discharge value closed
Do not attempt to start a Pump which is windmilling running backwards due to slurry
flowing backwards through the pump, imparting rotation into the impeller and drive

Review Exercise
Complete each of these questions and review your answers with your Instructor.
1. What is the purpose of the Slurry Pump?
2. List 4 main components of a Slurry Pump
3. What force is used to accelerate the slurry through the Pump housing?
4. List the two types of drives commonly used on Slurry Pumps

Slurry Pump Learner Guide
5. State 2 applications for Slurry Pumps in cement manufacturing
6. Describe 5 inspection points for a Slurry Pump
7. Describe 3 conditions that could result in a loss of Pump capacity

8. List 5 safety precautions associated with operating a Slurry Pump

Slurry Pump: Learner Guide

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Field Operator Certification

Self-Directed/In Class Learning Objectives

On-The-Job Learning Objectives

Field Operator Certification 2/10/2017 1

2 2/10/2017 Slurry Pump Learner Guide

Field Operator Certification 2/10/2017 3

Slurry Pumps Learning Content

4 2/10/2017 Slurry Pump Learner Guide

Slurry Pump Drives

Field Operator Certification 2/10/2017 5

6 2/10/2017 Slurry Pump Learner Guide

Slurry Pump Running Inspection

Field Operator Certification 2/10/2017 7

Slurry Pump Static Inspection

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Pump System Troubleshooting