Click on Warman Logo to go back to Menu WARMAN PUMPS ASSEMBLY, OPERATING AND MAINTENANCE INSTRUCTIONS PART 2Q SLURRY JET PUMPS TYPES JPC AND JPH PC2Q

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1 Click on Warman Logo to go back to Menu WARMAN PUMPS ASSEMBLY, OPERATING AND MAINTENANCE INSTRUCTIONS PART 2Q SLURRY JET PUMPS TYPES JPC AND JPH PC2Q

2 WARMAN PUMPS ASSEMBLY, OPERATING AND MAINTENANCE INSTRUCTIONS PART 2Q SLURRY JET PUMPS TYPES 'JPC' AND JPH Issue Date: 1 April 2002 Information in this publication is subject to change without notice. This publication may not be reproduced in whole or in part by any process, electronic or otherwise, without the specific written consent of Research and Development Pty Limited. Copyright Research and Development Pty Limited 2002

3 SAFETY INFORMATION The following safety information relating to pump operation and maintenance should be carefully observed, and correct procedures followed, to avoid injuries to personnel, and damage to equipment. All statutory requirements relating to this equipment must be complied with at all times. DO NOT APPLY HEAT TO THE NOZZLE INSERTS OR OTHER ABRASION RESISTANT CAST IRON PARTS TO ASSIST REMOVAL. APPLICATION OF HEAT MAY RESULT IN SHATTERING OF THE MATERIAL, RESULTING IN INJURY OR EQUIPMENT DAMAGE. WHERE AUXILIARY EQUIPMENT IS ASSOCIATED WITH A JET PUMP (eg MOTORS, DRIVE BELTS, DRIVE COUPLINGS, SPEED REDUCERS, VARIABLE SPEED DRIVES, ETC), ALL RELEVANT INSTRUCTION MANUALS SHOULD BE CONSULTED, AND RECOMMENDED PROCEDURES IMPLEMENTED, DURING INSTALLATION, OPERATION AND MAINTENANCE OF THE PUMP SYSTEM. ISSUE DATE: 1 April 2002

4 CONTENTS PART 2Q Page 1. INTRODUCTION APPLICATION AND FEATURES OF TYPE JPC AND JPH SLURRY JET PUMPS IDENTIFICATION OF PUMP AND PARTS PUMP ASSEMBLY INSTRUCTIONS Nozzle Assembly Closed Header Nozzle Holder Assembly Fitting of Mixing Chamber Fitting of Diffuser PIPEWORK PUMP OPERATION Pump Priming Normal Pump Start-up Procedure Abnormal Pump Start-up Operating Faults Pump Shut-Down Procedure MAINTENANCE Running Maintenance Overhaul Maintenance SPARE PARTS 2-15 APPENDIX - WARMAN BASIC PART NUMBERS 2-16 ISSUE DATE: 1 April 2002

5 1. INTRODUCTION This publication,, comprises the Assembly, Operating, and Maintenance Instruction Manual for Warman Slurry Jet Pumps, Types JPC and JPH. These pumps, otherwise commonly described as eductors or ejectors, are static devices, which are energised by high pressure liquid, commonly termed the motive fluid, supplied to a nozzle in the Jet Pump. The motive fluid, usually water with low particle concentration, is commonly supplied from a centrifugal pump located apart from the Jet Pump. Slurry is induced into the region of the nozzle discharge, where it is energised by the nozzle jet, and discharges from the pump at a pressure intermediate between that of the nozzle supply and the slurry feed. 2. APPLICATION AND FEATURES OF TYPE JPC AND JPH SLURRY JET PUMPS These pumps are of heavy-duty construction, designed for continuous pumping of highly abrasive and corrosive slurries. They feature replaceable elements in wear resistant material in the high velocity regions immediately downstream of the nozzle discharge. They are characterised by design simplicity, minimum number of parts, and absence of any moving parts. The Type JPC Jet Pump is designed to receive slurry feed conveyed by a pipeline, where the pump is located at a point relatively remote from the source of the feed material. The body of the pump, adjacent the slurry inlet, is equipped with a removeable cover to give rapid access to the entrainment region to clear blockages caused by oversize particles in the feed. The Type JPH Jet Pump is designed for close coupling to a feed hopper which discharges slurry directly into the entrainment region of the pump. This pump commonly operates with substantially higher concentration of solid particles than the Type JPC pump, and incorporates a pump body of special design to avoid blockage caused by high slurry densities. If problems are experienced during pump operation, assistance should be sought from the nearest C.H. Warman Group office, or its local representative. Important design features of the range of Warman Slurry Jet Pumps include: No moving parts Compact and simple design Modular design for extended range of performance Easily replaceable parts Minimum number of components Rapid access to clear blockages ISSUE DATE: 1 April

6 3. IDENTIFICATION OF PUMP AND PARTS Each Warman pump has a nameplate attached to the frame, on which are stamped the pump serial number and identification code. The pump identification code is made up of digits and letters arranged as follows: PUMP SIZE PUMP TYPE FEED INLET TYPE (digits) (letters) (letters) (a) (b) (c) eg 150 JPC where: (a) PUMP SIZE represents the size of the pipe which connects to the pump discharge, ie 150 mms in the above example. (b) PUMP TYPE, JP indicates Jet Pump (c) FEED INLET TYPE, either C or H, defines the type of feed entry for which the pump is designed, viz C is designed to accept slurry feed from a pipeline or hopper H is designed to accept slurry feed from a hopper which discharges directly by gravity to the pump, with no dead-box regions. Each Warman Jet Pump part has a unique name and a three-digit Basic Part Number. Parts with the same name have the same Basic Part Number, regardless of pump size. For example, the Diffuser of every Warman Jet Pump has the Basic Part Number 414. Additional letters and numbers are added before and after the Basic Part Number to further define a component part of a particular pump. This expanded marking is identified as the Part Number, and represents a unique identification for each component part. The Part Number is normally cast or otherwise prominently marked on each part. For example, Part Number 150JP413-A05A identifies a Mixing Chamber to fit the casing of the 150JPC or 150JPH Warman Jet Pumps. Refer to the Component Diagram of the appropriate size of Warman Pump for complete identification and description of component parts. Part names and Basic Part Numbers are used in assembly instructions throughout this instruction manual. Warman Basic Part Numbers for all component parts of Type JPC and JPH Jet Pumps are listed in the Appendix of this publication. In all communications with the C.H. Warman Pump Group, or its representatives, and particularly when ordering spare parts, it is recommended that the correct component names and Part Numbers be used at all times to avoid supply of incorrect parts. The pump serial number should also be quoted if any doubt exists as to part identification. ISSUE DATE: 1 April

7 4. PUMP ASSEMBLY INSTRUCTIONS Reference to a Component Diagram for the particular pump being assembled will be of assistance in following the instructions outlined in the following sections. All parts dismantled during pump overhaul should be inspected to assess suitability for re-use, and identification of new parts should be checked. Parts suitable for re-use should be cleaned and painted. Matching faces should be free of rust, dirt, and burrs, and have a coating of antiseize compound applied prior to assembly. Small fasteners should preferably be replaced, and all threads coated with graphite grease before assembly. Replacement of all elastomer seals is recommended at major overhauls, as these materials tend to deteriorate with use. Exposure to direct and continuous sunlight will accelerate elastomer degradation. 4.1 NOZZLE ASSEMBLY - Refer Fig 1 In small Jet Pumps (50JP and 100JP) the Nozzle Assembly comprises a single component, viz. the Nozzle. In larger pumps, the Nozzle Assembly comprises a Nozzle Holder to which is fitted a Nozzle selected from a range of units differing only in the bore diameter. For single component Nozzles, proceed to Section NOZZLE HEXAGON CAP SCREW DOWEL PIN Fig 1 (26 lines) 412 NOZZLE HOLDER Fig. 1 ISSUE DATE: 1 April

8 Assembly of multi-component Nozzle Assemblies is described below. (i) Place NOZZLE HOLDER (412) on a bench surface, flange surface down. (ii) Select the NOZZLE (412), having the required bore diameter. Apply anti-seize compound to the spigot diameter of the Nozzle, and the corresponding recess diameter of the Nozzle Holder. Rest Nozzle on bench surface, with locating spigot uppermost. (iii) Take single DOWEL PIN, and tap firmly with hammer into corresponding hole in end face of Nozzle. (iv) Fit Nozzle to Nozzle Holder, engaging Dowel Pin and spigot on Nozzle, with corresponding hole and recess in Nozzle Holder. (v) Select appropriate HEXAGON CAP SCREWS, as defined in Component Diagram, and fit to holes in end of Nozzle. Engage thread in Nozzle Holder, and fully tighten to fasten Nozzle to Nozzle Holder. 4.2 CLOSED HEADER NOZZLE HOLDER ASSEMBLY - Refer Fig 2 This comprises fitting of the Nozzle Assembly and Flange Cover Plate (where appropriate) to flanged openings in the Closed Header-Nozzle Holder. The Flange Cover Plate, and corresponding opening in the Closed Header, are provided only in Type JPC Jet Pumps HEXAGON BOLT SPRING WASHER 416 CLOSED HEADER-NOZZLE HOLDER O-RING STRING 412 NOZZLE Fig 2 (26 lines) Fig NOZZLE HOLDER ISSUE DATE: 1 April

9 (i) (ii) Place CLOSED HEADER-NOZZLE HOLDER (416) on a horizontal surface, with axes of flanged openings parallel to the surface (3 flanged openings for Type JPH pumps, and 4 flanged openings for Type JPC pumps). Fit NOZZLE ASSEMBLY (or NOZZLE (412) for single component Nozzles) as follows: (a) Place Nozzle Assembly (or Nozzle for single component Nozzles) face down on bench, with conical surface upwards. (b) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to exposed groove on back face of NOZZLE HOLDER (412), adjacent conical surface, (or to inner periphery of Nozzle for single component Nozzles). (c) Fit O-Ring String to plane end face of Nozzle Holder (or Nozzle), if applicable. This O-Ring groove (not shown in Fig 2) is provided only in some pump sizes, as indicated in the appropriate Component Diagram. (1) Turn Nozzle (or Nozzle Assembly) over to rest on peripheral diameter and discharge end of Nozzle, and to expose other O-Ring groove on plane face of Nozzle Holder (or Nozzle). (2) Select second appropriate O-RING STRING, as defined in Component Diagram, and fit to exposed groove on plane face of Nozzle Holder (or Nozzle), preferably using contact cement adhesive. Apply adhesive to compression surface of O-Ring at about 4 or 6 points only to secure seal, and avoid undue restraint during compression. (d) Apply anti-seize compound to outer cylindrical surface intersecting periphery of conical surface of Nozzle Holder (or Nozzle), and to matching bore of Closed Header Nozzle Holder. (e) Take Nozzle Assembly (or Nozzle), and insert projecting conical end fully into flanged opening in Closed Header, to engage cylindrical surface of Nozzle Holder (or Nozzle) with corresponding bore of flanged opening, and to contact matching plane annular faces of Nozzle Holder and Closed Header. (f) Rotate Nozzle (or Nozzle Assembly), where appropriate, to align slots in rear face of Nozzle with corresponding holes in flange of Closed Header. (g) If required, fit two temporary bolts to clamp flanges of Nozzle Assembly and Closed Header, to prevent displacement of Nozzle Assembly. (iii) FOR TYPE JPC PUMPS ONLY - Fit FLANGE COVER (245) to Closed Header Nozzle Holder as follows: ISSUE DATE: 1 April

10 (a) Fit FLANGE COVER GASKET (204) to matching plane annular face of Closed Header, preferably using contact cement adhesive, and aligning matching bolt holes. (b) Fit Flange Cover to matching plane annular face of Closed Header, with markings on exposed outer face of Cover, and aligning matching bolt holes. (c) Select appropriate HEXAGON BOLTS, as defined in Component Diagram, and fit to holes in Flange Cover. Engage threads in Closed Header, and fully tighten. 4.3 FITTING OF MIXING CHAMBER - Refer Figs 3, 4 and For 50JPC and 50JPH Pumps only refer Fig 3. (i) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to outer diameter at end of MIXING CHAMBER (413) having inner bore radiused to end face. (ii) Apply anti-seize compound to locating spigot on exposed end of Mixing Chamber, and to matching recess in flanged end of CLOSED HEADER-NOZZLE HOLDER (416). O-RING STRING SPRING WASHER HEXAGON BOLT CLOSED HEADER- NOZZLE HOLDER 413 O-RING STRING Fig 3 (26 lines) 414 O-RING STRING Fig. 3 ISSUE DATE: 1 April

11 (iii) Fit end of Mixing Chamber, with O-Ring fitted, into matching opening in flanged face of Closed Header immediately opposite, and concentric with axis of Nozzle. Push Mixing Chamber into engagement with Closed Header until it is limited by compression of O-Ring For 350JPC and 350JPH Pumps only refer Fig 4. The construction of these pumps differs from other pump sizes in that the Mixing Chambers are enclosed within an outer housing, the Closed Header Mixing Chamber. NUT SPRING WASHER PLAIN WASHER HEXAGON BOLT NUT SPRING WASHER PLAIN WASHER HEXAGON BOLT 414 Fig 4 (26 lines) CLOSED HEADER- MIXING CHAMBER O-RING STRING Fig. 4 O-RING STRING 416 CLOSED HEADER- NOZZLE HOLDER (i) Lift non-flanged end of MIXING CHAMBER (413) and support on flanged end, with axis vertical. (ii) With CLOSED HEADER MIXING CHAMBER (416) supported from either flanged end, lift with hoist, and lower over Mixing Chamber, with axes coincident, until lower flanged end is supported on lower flange of MIXING CHAMBER (413). Adjust angular orientation for coincidence of bolt holes in both flanges. (iii) Select appropriate HEXAGON BOLTS, nuts, and washers, as defined in Component Diagram, and fit 6 of 12 Bolts to holes from upper flange. Fit Plain Washers adjacent Bolt head, and Nuts only at free ends. Leave Nuts hand tight only at this stage. ISSUE DATE: 1 April

12 (iv) Attach hoist sling at upper end of CLOSED HEADER MIXING CHAMBER (416), and pivot about lower end until assembly is supported with axis horizontal. (v) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to groove in face of flange at end of MIXING CHAMBER (413). (vi) Support CLOSED HEADER MIXING CHAMBER (416) from a hoist, with axis horizontal, and position with flanged end of MIXING CHAMBER (413) adjacent flanged end of CLOSED HEADER NOZZLE HOLDER (416), opposite the end with Nozzle assembly fitted, and with axes coincident. (vii) Apply anti-seize compound to locating spigot on exposed end of Mixing Chamber, and to matching recess in flanged end of Closed Header. (viii) Carefully remove nuts from Hexagon Bolts mounted in Mixing Chamber flange, leaving bolts in position. (ix) With CLOSED HEADER MIXING CHAMBER (416) supported on a hoist, with axis horizontal, move axially to engage spigot of Mixing Chamber, protruding from flanged end, with adjacent bore of flanged end of CLOSED HEADER NOZZLE HOLDER (416). Adjust angular orientation for coincidence of bolt holes in flange, and ensure full engagement of Bolts with holes in flanges. Fit Spring Washers, and Nuts to Bolts, and fully tighten. (x) Fit remaining 6 Hexagon Bolts, with Washers and Nuts, to flanges to fully secure Mixing Chamber assembly to Closed Header-Nozzle Holder For All Other Pump Sizes refer Fig 5. (i) Fit one SPLIT FLANGE (221) to Mixing Chamber as described below: (a) Separate Flange halves by unscrewing diametral fastening bolts. (b) Place Flange halves around Mixing Chamber, adjacent the plane annular face of either end shoulder. Note that markings on Flange faces should be on side remote from end of Chamber. (c) Fit diametral fastening bolts to Split Flange, and fully tighten. (ii) Fit second SPLIT FLANGE (221) to other end of Mixing Chamber as described in (i). (iii) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to extended spigot at end of MIXING CHAMBER (413) having inner bore radiused to end face. ISSUE DATE: 1 April

13 (iv) Apply anti-seize compound to locating spigot on exposed end of Mixing Chamber, and to matching recess in flanged end of CLOSED HEADER-NOZZLE HOLDER (416). (v) Lift Mixing Chamber, using a hoist, and fit end with extended spigot (with O- Ring fitted) into matching opening in flanged face of Closed Header-Nozzle Holder, immediately opposite, and concentric with axis of Nozzle. (vi) Select appropriate HEXAGON BOLTS and washers, as defined in Component Diagram, and fit to holes in Split-Flange. Engage threads in flange of Closed Header-Nozzle Holder, and tighten carefully to ensure that shoulder of Mixing Chamber is uniformly in contact with flange face. NUT SPRING WASHER PLAIN WASHER HEXAGON BOLT 416 CLOSED HEADER- NOZZLE HOLDER SPRING WASHER HEXAGON BOLT 413 Fig 5 (26 lines) O-RING STRING O-RING STRING O-RING STRING Fig FITTING OF DIFFUSER - Refer Figs 3, 4 and 5 (i) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to exposed spigot at end of MIXING CHAMBER (413), preferably using contact cement adhesive to retain in place. Apply adhesive to compression surface of O-Ring at about 4 or 6 points only to secure seal, and avoid undue restraint during compression. (ii) Lift DIFFUSER (414) with axis horizontal, using a hoist, and position with smaller bore end adjacent exposed end of Mixing Chamber, and with axes coincident. ISSUE DATE: 1 April

14 (iii) Apply anti-seize compound to locating spigot on exposed end of Mixing Chamber, and to matching recess in flanged end of Diffuser. (iv) Engage spigot on end of Mixing Chamber with recess in flanged end of Diffuser. (v) For 50JPC and 50JPH Pumps only refer Fig 3. Select appropriate HEXAGON BOLTS (4) and spring washers (4), as defined in Component Diagram, and fit to slots in flange of Diffuser. Adjust angular orientation of Diffuser for coincidence of bolt holes in flanges, Engage threads in flange of Closed Header-Nozzle Holder, and tighten carefully to ensure that end shoulders of Mixing Chamber remain uniformly in contact with matching flange faces. (vi) For 350JPC and 350JPH Pumps only refer Fig 4. Select appropriate HEXAGON BOLTS (12) (each including nut, plain washer and spring washer), as defined in Component Diagram, and fit to slots in flange of Diffuser, engaging holes in flange of Closed Header-Mixing Chamber. Fit spring washers and nuts, and progressively tighten in a sequential manner to full load. (vii) For All Other Pump Sizes refer Fig 5. Select appropriate HEXAGON BOLTS (each including nut, plain washer and spring washer), as defined in Component Diagram, and fit to slots in flange of Diffuser, engaging holes in SPLIT FLANGE (221). Fit spring washers and nuts, and progressively tighten in a sequential manner to full load, ensuring that end shoulders of Mixing Chamber remain uniformly in contact with matching flange faces. (viii) For All Pump Sizes (1) Fit SPLIT FLANGE (221) to Diffuser as described below: (a) Select appropriate Split Flange, as defined in Component Diagram, and separate Flange halves by unscrewing diametral fastening bolts. (b) Place Flange halves around Diffuser, with face of Flange adjacent the plane annular face of end shoulder adjacent open end of Diffuser. Note that markings on Flange faces should be on side remote from end of Chamber. (c) Fit diametral fastening bolts to Split Flange, and fully tighten. (2) Select appropriate O-RING STRING, as defined in Component Diagram, and fit to groove in exposed end of Diffuser, preferably using contact cement adhesive to retain in place. Apply adhesive to compression surface of O-Ring at ISSUE DATE: 1 April

15 5. PIPEWORK about 4 or 6 points only to secure seal, and avoid undue restraint during compression. (3) The Warman Slurry Jet Pump is now fully assembled, and ready for connection to system pipework. Pipelines and valves should be correctly aligned with pump flanges, and supported independently of the pump. The piping system should be designed to minimise transfer of loads from the piping to the pump flanges. (a) Flanges Pipework flanges mating with the nozzle feed, and slurry intake and discharge should have flat faces to provide satisfactory backup support and compression of flange seals to prevent leakage. All pump connecting flanges comply with SABS standards for 1000 kpa pressure rating. (b) Intake Piping The length of intake pipe to the pump should be as small as possible. It is also important to ensure that all pipe joints are airtight to ensure optimal performance of the Jet pump in suction lift applications. Relatively long intake piping should be avoided, as this will impact negatively on pump performance. 6. PUMP OPERATION The main requirements for efficient operation of Warman Slurry Jet Pumps are as follows: Nozzle feed pump is properly maintained to ensure constant supply pressure at the Nozzle Holder flange. Nozzle and Mixing Chamber are replaced when abrasive wear causes excessive reduction in discharge pressure or slurry flowrate. Flow passages immediately downstream of the nozzle discharge remain clear of blockages by large particles. High density of suction feed is maintained by appropriate submergence of the suction pipe intake, or by provision of suitable agitation adjacent the pipe entry. 6.1 Pump Priming Jet pumps are inherently self priming, and can generally be started with an empty inlet pipe, ISSUE DATE: 1 April

16 provided that the entry to the pipe is submerged. In the hopper feed arrangement (Type JPH pump), the Jet Pump can generally be started under full load conditions. 6.2 Normal Pump Start-up Procedure (i) Ensure that slurry in the region of the suction pipe entry is not compacted, and able to flow readily into the pipe. In applications where separate means are provided to suspend solids at the pipe entry, this should be activated before starting the Nozzle Feed Pump. (ii) It is good practice to start up pumps on water, or reduced slurry concentration where possible, before introducing slurry into the feed. On shutting down, it is desirable to replace the slurry feed with water for a short period before pump shut down to allow solids to be flushed from the pipework. This applies in particular to applications having relatively long intake or discharge piping. (iii) Start Nozzle Feed Pump. If the Jet Pump inlet is flooded, and conditions at the inlet pipe entry are satisfactory, normal pump operation will be established almost immediately. If the Jet Pump inlet operates under suction lift conditions, normal pump operation will be delayed until all air in the suction line is entrained. 6.3 Abnormal Pump Start-up Failure of a pump to prime, or to deliver the rated pressure or flowrate may be caused by one or more of the following faults: (a) Intake or Discharge Pipe Blocked - If the pump has not been operated for some time, slurry may have settled in the intake or discharge pipe, or around the pipe entry. (b) Blockage inside pump - This may be caused by bridging of coarse particles in the region immediately downstream of the nozzle exit. (c) Low nozzle feed pressure This indicates a problem with the nozzle feed pump, or excessive wear of the Nozzle. 6.4 Operating Faults Slurry Jet Pumps are mechanically simple devices, and should be relatively free of operating problems caused directly by the pump. Most operating problems experienced are caused by factors external to the pump, affecting the suction, discharge, or nozzle supply pipelines. ISSUE DATE: 1 April

17 (a) Blockage within pump Flow of slurry may be partially or fully disrupted by bridging of coarse particles in the region immediately downstream of the nozzle exit, at entry to the Mixing Chamber. In Type JPC pumps the blockage may be manually cleared by removal of the Flange Cover in the Closed Header-Nozzle Holder, located diametrally opposite the flanged slurry inlet passage. The Flange Cover is not provided on Type JPH pumps, and access to nozzle exit region is from the hopper or removeable connecting pipe mounted directly above the flanged slurry inlet passage. (b) Loss of inlet submergence Pumps may periodically lose their prime if slurry level in the intake hopper or sump reduces sufficiently to allow air to be induced into the intake pipe. This may require modification of the inlet piping at entry to avoid this condition. (c) Blocked intake pipe The presence of foreign material or very coarse solid material can readily cause obstruction of the pump intake. A partial obstruction may result in reduced flowrate, and a reduction in pressure at the pump inlet. (d) Blocked discharge pipe This may be caused by abnormally high concentration of coarse particles in the discharge pipe, or by the liquid velocity in the discharge pipe being too low to transport the solids. Such a blockage will typically be indicated by a partial or complete reduction in flowrate. (e) Cavitation in inlet passage This may occur with pumps operating with a suction lift condition, and indicates that the suction lift is excessive for the pump operating conditions. Its effect is to cause reduction in discharge flowrate. (f) Worn Nozzle This condition will cause an increase in Jet Pump discharge pressure, and flowrate. Power consumed by the Nozzle Feed Pump will increase, and could ultimately cause overloading of the drive motor. (g) Worn Mixing Chamber This condition will cause a reduction in Jet Pump discharge pressure, and flowrate. 6.5 Pump Shut-Down Procedure The following procedure is recommended for shutting down a pump: (a) (b) (c) Where possible, replace slurry feed with water, or reduce the concentration of solids if possible, immediately prior to shut-down for a sufficient time to flush all slurry from the system piping. Shut down the nozzle feed pump. Close valves (if any). ISSUE DATE: 1 April

18 7. MAINTENANCE 7.1 Running Maintenance Warman Slurry Jet Pumps are static devices, of heavy duty construction, and when correctly installed and operated should give extended trouble-free service with minimum maintenance requirements. Routine maintenance is likely to be required only for the nozzle feed pump, which is commonly a centrifugal pump. 7.2 Overhaul Maintenance Abrasive wear rate in slurry jet pumps is normally relatively low, resulting in long wear life of replaceable pump parts. When pump wear has resulted in reduction of performance to an unsatisfactory level, or leakage due to wall perforation, the pump should be dismantled for inspection and replacement of wearing parts (Nozzle, Mixing Chamber, Diffuser) Dismantling Pump Isolate the pump from the pipework system, and thoroughly wash down. Procedures for removal of components from the pump are the reverse of the assembly procedures described in Section 4. of this Manual Replacement of Pump Wear Parts The wear rate of slurry jet pump components is dependent on the type of pumping duty, and properties of solids being pumped, and solids content of nozzle feed water. Consequently the wear life of components such as Nozzle, Mixing Chamber and Diffuser, varies from one application to another, though replacement intervals are generally long. As wear progresses over the life of pump components, the discharge head and flowrate generally decrease with Mixing Chamber wear, and increase with Nozzle wear. Nozzle wear results in an increase in power consumed by the Nozzle Feed Pump, and could cause motor overloading. As wear of these pump components progresses, the efficiency of Jet Pump operation reduces, requiring increased power consumption to maintain a steady pump operating condition. At a point in the life cycle of casing components, pump flowrate may become inadequate, flow velocity may become too low to effectively transport the slurry, or power consumed by the Nozzle Feed Pump may become excessive. When any of these conditions occur the pump should be dismantled for inspection of wear parts. Refer to Section 4. of the Instruction Manual for installation details of wearing parts. ISSUE DATE: 1 April

19 8. SPARE PARTS Spare parts for Warman Jet Pumps comprise Nozzles, Mixing Chambers, and Diffusers. The wear life of these parts is dependent upon the particular operating duty, and characteristics of the solid material being pumped, though relatively long wear lives are generally experienced for these components before replacement is warranted. Nozzles are available in a range of bore sizes to provide variation in the range of pump operating characteristics. Increase in Nozzle bore size is associated with increased discharge pressure and flowrate of the Jet Pump, and with increased power consumption of the Nozzle Feed Pump. ISSUE DATE: 1 April

20 APPENDIX WARMAN BASIC PART NUMBERS WARMAN STANDARD BASIC PART No. WARMAN PART NAME MATERIAL CODE Flange Cover Gasket 221 E02 Split Flange 245 E02 Flange Cover 412 A05A Nozzle 412 G01 Nozzle Holder 413 A05A Mixing Chamber 414 A05A Diffuser 416 D20 Closed Header-Nozzle Holder 416 E02 Closed Header-Mixing Chamber - - Dowel Pin - - Hexagon Bolts - - Hexagon Cap Screws - - O-Ring String ISSUE DATE: 1 April