FLSmidth Krebs Chile Ltda.

Avda. Américo Vespucio 2760-D • Conchalí, Santiago • Chile

Tel +56 2 463 83 00 • Fax + 56 2 463 8383
www.krebs.com
HU U

July 26, 2010

INSTALLATION, OPERATION
AND MAINTENANCE MANUAL

Krebs slurryMAX

6X6-17 COMPLETE PUMPS

SERIAL NUMBERS: KM04579 - KM04580

FOR
CORI PUNO S. A.

P. O. NUMBER: L20100474

SALES ENGINEER: FLSmidth Krebs Chile Ltda. [email protected]

 ASSEMBLY

AND

MAINTENANCE

INSTRUCTIONS

FOR
FLSMIDTH
KREBS slurryMAX™ PUMPS

WITH POWER FRAMES

AND BEARING ASSEMBLIES


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 1
 TABLE OF CONTENTS

SECTION PAGE

1 GENERAL
1.1 INTRODUCTION 4
1.2 SPECIAL WARNINGS 4

2 CONTACT INFORMATION
2.1 CORPORATE OFFICE 4
2.2 REGIONAL REPRESENTATIVE OFFICE 4

3 SAFETY PRECAUTIONS 5

4 ON-SITE INSTALLATION
4.1 FOUNDATIONS 5
4.2 LEVELING THE BASEPLATE 6
4.3 ANCHORING THE BASEPLATE 6
4.4 ALIGNING THE PUMP THE WITH DRIVE ARRANGEMENT 7
4.5 CONNECTING THE PIPING 7

5 COMMISSIONING
5.1 AUXILLARY CONNECTIONS 7
5.2 MOTOR ROTATION CHECK 8
5.3 LUBRICATION 8
5.4 SHAFT SEAL CHECK 9

6 START-UP 10

7 SHUT-DOWN 10

8 STORAGE
8.1 HANDLING OF RUBBER COMPONENTS 11
8.2 HANDLING OF MECHANICAL COMPONENTS 11

9 POWER FRAME ASSEMBLY

9.1 MMAA-MMD FRAMES 12

10 WET-END ASSEMBLY
GENERAL NOTE 14
10.1 GLAND SIDE CASING AND SHAFT PREP 14
10.2 GLAND ARRANGEMENT 15
10.3 GLAND SIDE CASING LINER 17
10.4 IMPELLER 17
10.5 SUCTION SIDE CASING ASSEMBLY 18


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 2
10.6 ASSEMBLY OF SUCTION SIDE CASING TO GLAND SIDE
CASING 19
10.7 IMPELLER ADJUSTMENT 19

11 MAINTENANCE
11.1 ROUTINE MAINTENANCE 20
11.2 WEAR RING ADJUSTMENT 20
11.3 SHAFT SEAL ADJUSTMENT 20
11.4 BEARING LUBRICATION 21

12 PARTS REPLACEMENT
12.1 IMPELLER 22

13 TROUBLESHOOTING
13.1 DURING ASSEMBLY 23
13.2 ON INITIAL START-UP 24
13.3 DURING OPERATION 24


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 3
1 GENERAL

1.1 INTRODUCTION

This manual contains important information for installation, operation, and

maintenance of the slurryMAX™ pump. Instructions contained in this
manual must be reviewed and followed to ensure safety and extended
reliability from your slurryMAX™ pump.

1.2 SPECIAL WARNINGS

FLSmidth Krebs millMAX™ will not be liable nor assume responsibility for
any damages, or down-time caused by a failure to follow procedures,
warnings, or cautions outlined in this manual. FLSmidth Krebs millMAX™
retains the right to update and modify this manual at any time seen fit, and
will not be held liable for any omissions or errors, and will not accept any
claim for consequential damages.

This slurryMAX™ pump must not be operated beyond the rated conditions
for which it was sold.

2 CONTACT INFORMATION

2.1 CORPORATE OFFICE

FLSMIDTH
KREBS ENGINEERS
5505 West Gillette Road
Tucson, AZ 85743
Contact: Ricky McGahee
Phone (520) 744-8200 Fax: (520) 744-8300
[email protected]

2.2 REGIONAL REPRESENTATIVE OFFICE


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 4
3 SAFETY PRECAUTIONS

All slurryMAX™ pumps are designed for safe and long-term reliable
operation. A pump is a pressure-containing device that has rotating parts,
which may possess many possible hazards. It is recommended that the
slurryMAX™ pump only be serviced by qualified personnel such as
Operators and Maintenance personnel who recognize the possible
hazards that can be encountered while performing service on a pump.

Damage or destruction to pump components, and Personal Injuries

including possible loss of limb or life, may be a result of not
following the precautions outlined below.

 Caution must be made that the motor rotation is correct for pump rotation.
Starting of the motor with incorrect rotation may cause the impeller to
unthread from the pump shaft and rupture the casing, which may cause
personal injury. With the pump disconnected from the motor, verify that
the motor rotation is correct as per section 5.2.

 Never operate a pump without the drive guard or safety devices properly
installed.

 Always perform a lockout / tag-out of the power when drive guards are
removed, or disassembly maintenance is being performed.

 Never operate the slurryMAX™ pump with the suction or discharge valves
closed.

 Never apply heat to the impeller for disassembly from the pump shaft, as
there is risk of the impeller exploding from trapped liquid, which could
cause serious injury.

 Never lift from a single point. Lifting lugs, and tapped holes (for eyebolts)
are intended for lifting only individual parts and must not be used to lift the
entire pump assembly.

 Do not thermal shock the slurryMAX™ pump by feeding with very hot or
cold liquids. Thermal shock will cause damage to internal components,
and may rupture the pump impeller.

4 ON-SITE INSTALLATION

4.1 FOUNDATIONS

Prior to the installation of a pump it is necessary that a proper foundation

be in place. The foundation is necessary to support and anchor the pump
from all pumping and motor loads and to absorb vibration during start-up
and while running.

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 5
 Before mounting the pump base it is important to ensure that the
foundation adheres to the following:

 The mass of the foundation is at least 3 times greater than the mass of the
pump/drive assembly.

 The concrete slab conforms to local building codes, contractor’s

requirements, and is within dimensional tolerances.

 The foundation has been given adequate time to set and dry.

 Anchor bolts have been located properly.

The top surface of the foundation should be clean and wet-down for 24
hours prior to mounting. It may also be desirable to remove the top
cement-rich layer of the foundation. These steps promote a strong bond
between the concrete and the grout.

4.2 LEVELING THE BASEPLATE

Rest the baseplate on shims with ¾” to 1 ½” clearance above the

foundation. These shims need to be placed at every anchor bolt location
and not to exceed 2 ½ feet (0.75 meters) apart. Add or remove shims as
needed so that the machined surfaces of the baseplate are level.

4.3 ANCHORING THE BASEPLATE

Before grouting perform the following:

 Snug the anchor bolts enough to cease movement, but do not over-
tighten.

 Build a dam to contain the grout where needed.

 Avoid stress concentrations by softening sharp edges.

Grout the base to the foundation using a non-shrink, free-flow grout for
heavy-duty machinery. To avoid air pockets always pour the grout from
one side rather than “meeting in the middle”. Fill the anchor bolt holes
completely, and make sure there are no gaps underneath or around the
base. Completely fill the inner area of the base as well, however it is ok to
use standard concrete in this area. Vibrating the baseplate during
grouting can aid in removing trapped air, but do not vibrate so violently
that the base changes position or loses level.

Once poured allow the grout to dry for the length of time prescribed by the
grout manufacturer. Do not completely tighten the anchor bolts until the
grout has finished curing.

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 6
4.4 ALIGNING THE PUMP WITH THE DRIVE ARRANGEMENT

It is important that the pump shaft be properly aligned with the motor. As
misaligned v-belt drives will cause excessive belt wear, and misaligned
direct-coupled drives will cause unnecessary vibrations.

4.4.A BELT-DRIVEN ARRANGEMENT

The motor sheave and the pump sheave must be adequately aligned and
the belts properly tensioned. Consult the v-belt drive insert in this manual
for details.

4.4.B IN-LINE COUPLED ARRANGEMENT

It is crucial that the shafts of any direct coupled assembly components are
aligned to within the coupling manufacturer’s specs. FLSmidth Krebs
Engineers leaves the method for performing this task to the discretion of
the installer, however a laser alignment system is recommended for
greatest accuracy. Consult the coupling insert in this manual for details.

4.4.C SOFT FOOT ALLOWANCES

Before bolting any components to the base or foundations, check for soft
foot. This is best accomplished by the use of a feeler gauge. Maximum
allowable soft foot for the pump pedestal feet is 2mm (.080”). Maximum
allowable soft foot for motors and gear reduces is 0.1mm (.004”). Use
shims if soft foot is greater than allowances stated above.

4.5 CONNECTING THE PIPING

It is important that the piping is the correct size, properly fitted, and
supported, so no strain or reaction forces are imposed onto the pump.

Also, it is recommended that a removable section of pipe of sufficient

length be placed onto the suction side of the pump. This will facilitate
easier removal of the pump casing when replacing worn parts.

5 COMMISSIONING

Before starting your slurryMAX™ pump for the first time, make sure that the
following steps are taken:

5.1 AUXILIARY CONNECTIONS

 Make sure the motor is properly connected to the appropriate electrical

power supply, and that connections conform to local regulations.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 7
  Make sure that the auxiliary power connections are connected,
functioning, and in the off position.

5.2 MOTOR ROTATION CHECK

It is important to verify that the motor rotation is correct, and this

verification is performed with the motor disconnected from the pump.
Incorrect motor rotation can be a result of improper wire connections.
CAUTION: Ensure that the motor rotation is correct for pump
rotation. Starting the motor with incorrect rotation may cause the
impeller to unthread from the pump shaft, which may cause personal
injury. With the pump disconnected from the motor, verify that the
motor rotation is correct.

 With the electrical controls in the off, locked-out, and tagged-out position,
make sure the motor and pump rotate freely by hand.

 Remove all of the v-belts or disconnect the shaft coupling if direct drive.

 Remove the electrical locks and tags. Start the motor to verify the motor
rotation is correct. If not correct reconnect the wiring as necessary.

 Reinstall the electrical locks and tags. Reinstall the v-belts or shaft
coupling, and reaffirm shaft alignment.

5.3 LUBRICATION

Bearing assemblies lubricated with grease are pre-lubricated at the

factory. Additional grease at start-up should not be necessary. The
grease nipples on the bearing housing end covers lubricate the seal and
flinger area to provide a grease barrier that prevents contamination of
slurry and/or gland water to the bearings. These should be greased
frequently so that clean grease exudes from the rim of the flinger. It is not
possible to overgrease this area. Use an N.L.G.I. Grade 2 grease with
extreme pressure additives, oil viscosity of ISO 150-220, and a minimum
dropping point of 177°C (350°F). Suggested brands are:
Castrol EPL2 Lubriplate 730-2
Chevron Dura-Lith EP2 Lubriplate 1200-2
Conoco Phillips Dynalife L-EP2 Mobil Mobilux EP2
Conoco Phillips Super-STA 2 Shell Alvania EP2
LPS Thermaplex Multi-Purpose


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 8
5.4 SHAFT SEAL CHECK

5.4.A CENTRIFUGAL SEAL

 For centrifugal sealed pumps, the gland should be adjusted just tight
enough that there is no leakage while the pump is stopped. The gland
packing in the dry gland centrifugal seal design is required to run dry and
therefore has to be lubricated internally. Using the same grease as
recommended for the bearings in section 5.3, charge the grease nipple on
the expeller ring at startup and every two days, until resistance at the
grease gun lever is felt.

5.4.B WATER FLUSH SEAL

Gland water supply needs to be connected to the seal water port on the stuffing
box. (NOTE: Some stuffing boxes will have two pipe-thread ports. The port
closer to the drive side of the box is for use in low-flow situations, while the port
closer to the pump side of the box is for use in full-flow situations. Whichever
port will not be used must be plugged.)

 Gland water must be clean, free from sand, rust, etc…as these abrasive
particles will greatly reduce the wear life of the shaft sleeve. The gland
water should be available at a pressure of 10psi. (maximum) above the
discharge pressure of the pump.

 Maximum recommended flow rate should be as follows:

Power Frame High Low

MAA / CMC 8gpm 0.15gpm
MMA / CMD 15gpm 0.2gpm
MMB / CME 20gpm 0.3gpm
MMC / CMF 25gpm 0.5gpm
MMD / CMG 30gpm 0.6gpm

 The gland water should be pressure controlled, not flow controlled. The
amount of gland water flow should be adjusted to the minimum required to
provide cooling. This will often result in flow rates much lower than the
ones listed above. The gland follower should be adjusted enough to allow
a small flow of gland water along the shaft while the pump is running.

5.4.C MECHANICAL SEAL

Mechanical seals are built to precision tolerances, and require special care for
proper operation. If a mechanical seal is mounted to your pump please refer to
the appendix containing details of the appropriate seal for complete instructions
on start-up & maintenance.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 9
6 START-UP

 Whenever possible the pump should be started up on water before slurry

or solids are introduced into the feed.

 Fully open the inlet valve and ensure that water is available at the pump
inlet.

 On water flush sealed pumps check that the gland water system is
operating and that gland water is available at the correct pressure and
flow rate.

 When the pump is running check the gland water leakage. If leakage is
excessive the gland screws should be tightened to reduce the flow to the
required level. If the gland shows signs of heating the gland screws
should be loosened slightly. If the gland continues to heat up to the extent
that steam and/or smoke is emitted, the pump must be stopped and the
gland allowed to cool before re-starting.

 Adjust the casing wear ring. The wear ring (25) must be adjusted on initial
start-up, as this critical clearance can only be set while the pump is
operating. CAUTION: Over adjustment will give increased grinding
and wear on mating faces of impeller and wear ring with a
corresponding reduction in life.

 The wear ring screws (31) should be tightened clockwise two flats each,
until contact / rubbing resistance is felt at all of the wear ring screws.
(NOTE: This will occur when the wear ring contacts the impeller, and the
wear ring screws are evenly adjusted).

 Loosen each wear ring screw by one flat each (or just enough that no
rubbing is felt). This will set the optimum clearance.

 If pressure gauges are available check the suction and discharge

pressures. (NOTE: changes in these pressures can be used as a
guideline or indicator for routine adjustment of the wear ring).

7 SHUT-DOWN

 Before shutting down the pump it should be allowed to run for a short
period of time on clean water to remove the solids from the pump and
clear the system.

 If a drain valve is fitted in the suction line this should be left open while the
pump is out of use.

 If the pump is to be taken out of service for some time, check section 8 for
correct storage procedure.

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 10
8 PUMP STORAGE

8.1. HANDLING OF RUBBER COMPONENTS

 Avoid storage conditions in temperatures above 38°C (100°F). Moist air in

absence of sunlight is most desirable.

 Do not store products where temperature change is faster than 6°C

(10°F).

 Do not handle or allow covered products to bump other items when

temperatures are below 0°C (32°F).

 Do not allow rubber covered items to come in contact with oils, solvents,
gasoline, lubricating oils, napthas, lacquer products, toluol, benzene, coal
tars, etc.

 Do not store in direct sunlight. In emergencies, cover products with

tarpaulins.

 Do not store near electrical equipment, operating motors, transformers

and power centers. Ozone deteriorates rubber very rapidly.

 Do not attach slings or any lifting device directly against any rubber
covered surfaces. Cushion or pad lifting devices with burlap or wood.

 Do not permit covered products to be bumped or struck by sharp items,

which will bruise or pierce rubber, allowing corrosive solutions to
penetrate.

 Do not stack covered products without proper support for each item.
Permanent deformation will result.

8.2. HANDLING OF MECHANICAL COMPONENTS

 It is recommended that a pump be stored indoors, and protected from

extreme temperatures.

 Rotate the shaft several turns once a month.

 Once every 6 months purge the bearing seals with grease to prevent the
bearing from being contaminated with dirt and moisture.

 Protect all external machined surfaces with a removable rust preventative

coating.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 11
  Cover the suction and discharge connections, unless connected to piping.

 For outdoor storage, cover the pump with a weatherproof tarpaulin that will
allow air circulation.

 Prior to start-up ensure the pump and its components are in a satisfactory
condition.

9 POWER FRAME ASSEMBLY

9.1 MMAA-MMD FRAMES

9.1.A BEARING ASSEMBLY

 Stand the shaft on end, impeller end up. Heat the bearing cone to roughly
104° C (220° F) using an induction heater and drop it into position on the
shaft with small diameter towards the shaft shoulder. Make sure it seats
up against the shoulder and tap into position as necessary.

 Fit a suitable spacer over the shaft to retain the bearing cone against the
shaft shoulder using a nut on the shaft threads to tension.

 Turn the shaft over and stand it on the impeller end.

 Fit a bearing cup in each end of the bearing housing using Loctite®
“Retaining Compound” (No. 635) to keep the cups from dropping out when
the bearing housing is inverted. It may be necessary to tap the cups down
with a soft metal drift.

 Place two lifting eyes at one end of the housing (in opposing end cover
bolt holes) and lower it over the shaft until all weight is taken on the
bearing cone.

 Heat the next bearing cone to 104° C (220° F) using an induction heater
and drop it onto the shaft with small diameter towards the bearing cup,
then tap it down into position against the cup.

 Mount a dial indicator on the end of the housing with the actuating pin
against the end of the shaft. Rotate the housing by hand a minimum 10
times for the bearings to align correctly. (NOTE: make sure the end of the
shaft is free of dirt and burrs before setting up the indicator).

 Take the weight on the two lifting eyes and check the endplay. To reduce
the clearance, take the weight with the shaft on the floor and tap the
bearing down the shaft. For more clearance, take the weight on the
housing and knock the shaft down through the bearing. Endplay (cold)
should be as follows:

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 12
 MMAA .03mm - .05mm (.001” - .002”)
MMA .05mm - .1mm (.002” - .004”)
MMB .08mm - .13mm (.003” - .005”)
MMC .1mm - .15mm (.004” - .006”)
MMD .15mm - .2mm (.006” - .008”)

 When the required clearance has been set use a grease gun with a
narrow nozzle to fully pack both bearings with grease between each roller.
See section 5.3 for specifications and suggested brands. After this, pump
grease through both grease nipples in the bearing housing until the grease
that was packed between the rollers begins to be pushed out.

 Lay the unit on its side, (preferably in the pedestal) and remove the
retaining nut from the shaft thread, followed by the spacer.

 Fit a Waveseal, lip facing outward, into the recess of each housing end.
Apply a coat of silicone to the ends of the housing, followed by the end
cover. Once the end cover is seated properly fasten it with the correct
hardware.

 Slide the flinger, small O.D. end first, onto the impeller end of the shaft, up
to the bearing. Grease the OD of the flinger that fits through the seal
before installation.

 Fit a dowel pin in the hole on the face of the second flinger and slide into
position, small O.D. end first, over the locknut thread and up to the bearing
on the other end of the housing.

 Locate a locknut on the locknut thread with the flat face toward the flinger.
Engage the flinger dowel pin in one of the locknut slots and tighten against
the bearing.

 Fit bearing lock washer flat end first on drive end of shaft, aligning the
inner tab with the keyway and against installed lock nut.

 Locate the second locknut on the locknut thread with the flat face
outwards and tighten securely in position. Bend one of the angled tangs
of the lock washer into a slot on the second lock nut.

9.1.B BEARING ASSEMBLY TO PEDESTAL

 Lubricate all bolts as necessary.

 Fit the adjusting screw through the hole at rear of base and tighten into
position with a nut and washer. Two additional nuts, with washers
between them, should then be spaced wide apart on the screw.

 Lower the bearing housing centrally into the saddle with the impeller end
of the shaft towards the front. Ensure that the housing adjusting lug

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 13
 locates correctly over the adjusting screw between the adjusting nuts and
washers.

 Fit two housing clamps in position over the housing. Draw the housing
clamp bolts up from the bottom of the pedestal and hold in position with
nuts and washers. Tighten them equally on either side to ensure correct
alignment of the shaft for subsequent alignment of the gland.

10 WET-END ASSEMBLY

GENERAL NOTE: Exercise care in the use of lubricants such as grease and
anti-seize compound when joining metal components together. Avoid getting
them on the rubber components.

10.1 GLAND SIDE CASING AND SHAFT PREP

 Locate the gland side casing (1) and install three base studs (38) in
tapped holes. The location of the base studs depends on the discharge
position of pump. Position the casing onto the three pedestal mounting
posts by fitting the base studs through the holes. Ensure that it fits flush to
the face of the posts then bolt it securely in place using the base stud
washers (40), and nuts (39).

 For a 6x4 slurryMAX going on a MMB power frame only, it is necessary to

bolt an adapter (1A) to the gland side casing (1) with (4) socket head bolts
(1B). Then, the three base studs (38) are fitted into the tapped holes of
the adapter (1A) as in the previous step. See the sketch on the next page
to clarify.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 14
 ASSEMBLED

1
1B 1A

 Fit a shaft seal O-ring, sleeve spacer O-ring or a gasket (23) (whichever
one is applicable to the pump being assembled) onto the shaft up against
the flinger. If a sleeve spacer (22) is required, fit it onto the shaft followed
by a shaft seal O-ring or a second sleeve spacer gasket (23).

10.2 GLAND ARRANGEMENT

The assembly of the gland arrangement should be carried out with the expeller
ring (centrifugal seal) or stuffing box (water-flush seal) resting on a flat surface
with the tapped holes facing upward.

10.2.A CENTRIFUGAL SEAL

 Thread the grease nipple (36) and gland studs (18) into the expeller ring
(33).

 Position the shaft sleeve (27) vertically in the bore of the expeller ring (33)
with the impeller end (smaller I.D.) down.

 Place the first ring of packing (26) around the shaft sleeve and into the
bore of the expeller ring. Then push it to the bottom and tamp it down
evenly.

 Completely fill the lantern ring (34) with grease to reduce grease gun
application required at start up, then insert the lantern ring over the shaft

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 15
 sleeve and slide it down against the packing. See section 5.3 for
recommended grease.

 Insert the remaining rings of packing with the end gaps staggered on
opposite sides of the bore and tamp down evenly.

 Fit the gland follower (16) over the shaft sleeve (27) and over the gland
studs (18). Install the gland stud nuts (41), with washers (17), onto the
gland studs. Tighten the 3 gland stud nuts evenly until they sandwich the
washers against the gland follower. DO NOT OVERTIGHTEN.

 Offer up the gland arrangement so that the shaft sleeve (27) slides over
the impeller shaft. Ensure that the expeller ring O.D. locates correctly into
the gland side casing such that the gland screws and the grease nipple
are positioned for easy access. Also ensure that a minimum air gap of
.38mm (.015”) exists between the expeller ring I.D. and the shaft sleeve
O.D. If necessary shim the expeller ring in the gland side casing as
required.

 Fit the shaft seal O-ring or gasket onto the end of the shaft up against the
shaft sleeve.

 Install the expeller (32) onto the shaft with the expeller vanes positioned
toward the expeller ring (33).

10.2.B WATER FLUSH SEAL

Some stuffing boxes will have two pipe-thread ports. The port closer to the
drive side of the box is for use in low-flow situations, while the port closer to the
pump side of the box is for use in full-flow situations. Whichever port will not be
used must be plugged. Some models require a close nipple and 45° elbow
installed on the sealing water port to allow connection of the water supply line.
Refer to the assembly drawing to determine.

 Position the shaft sleeve (27) vertically in the bore of the stuffing box (24)
with the impeller end (smaller I.D.) down.

 For high flow gland water, fit the following parts over the shaft sleeve and
into the stuffing box bore in this order:
1. Lantern Bush (21).
2. Packing Rings (26) with end gaps staggered on opposite sides of bore.
3. Gland Follower (16).

 For low flow gland water, fit the following parts over the shaft sleeve and
into the stuffing box bore in this order:
1. Neck Ring (21)
2. One ring of packing (26)
3. Lantern Ring (34)


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 16
 4. Remaining rings of packing (26) with end gaps staggered on opposite
sides of bore.
5. Gland Follower (16)

 Thread the gland screws (18) with washers (17) into the stuffing box (24),
and tighten evenly until the gland screws contact the gland follower, but
only finger tight. DO NOT OVERTIGHTEN. Some pumps use studs
instead of screws and the gland follower is installed in the same manner
as the centrifugal seal in 10.2.A.

 Offer up the gland arrangement so that the shaft sleeve (27) slides over
impeller shaft. Ensure that the stuffing box O.D. locates correctly in the
gland side casing and the gland screws, and the water flush port is
positioned for easy access.

 Fit O-ring or gaskets (20) to the end of the sleeve.

10.2.C MECHANICAL SEAL

For details of mechanical seal assembly consult the appendix containing details
of the appropriate seal.

10.3 GLAND SIDE CASING LINER

 Fit gland side casing liner (2) inside gland side casing (1) by aligning the
studs of the gland side casing liner with the drilled holes of the gland side
casing. Push the studs through the holes and ensure the outer dovetail
flange of the gland side casing liner fits flat in the cast recess of the gland
side casing. Ensure that discharge flange of gland side casing liner fits
flat in machined recess of gland side casing. Install washers (3) and nuts
(9) on studs and tighten evenly to fully seat the gland side casing liner in
the gland side casing. Before tightening nuts ensure that the gland
screws and grease nipple or water-flush port is positioned correctly by
rotating the gland assembly on the shaft.

 If the gland side casing liner fouls the expeller, adjust the bearing
assembly away from the impeller end and retighten the clamp bolts for
correct alignment of the gland before tightening the gland side casing liner
nuts.

10.4 IMPELLER

 Suspend the impeller (19) vertically and align it with the shaft thread.

 Rotate the shaft by means of the pulley or a spanner wrench in a

clockwise direction. If resistance is felt raise or lower the impeller slightly.
Rotate until tight.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 17
  If the impeller fouls the gland side casing liner (2) before contacting the
shaft sleeve (27), loosen the bearing assembly clamp bolts, adjust the
shaft forward and re-tighten the clamp bolts.

 It is important that the impeller is installed tightly. Otherwise the initial

torque at start-up may further screw on the impeller, fouling the gland side
casing liner backliner in the process, causing seizure or damage to the
gland side casing liner. Ensure that the sleeve spacer (22) and shaft
sleeve (27) rotate with the pump shaft after tightening the impeller. The
impeller can be fully tightened by two methods:

1. Lock the shaft and tighten the impeller with some form of leverage.

2. Lock the impeller and tighten the shaft with some form of leverage.

 Adjust the impeller (19) close to the gland side casing liner (2) to ensure
that the suction liner wear ring (25) does not foul the front face of the
impeller during installation of the suction side casing assembly.

 Loosen the housing clamp bolts on the bearing assembly.

 Use the adjusting screw to move the impeller axially towards the gland
side casing liner.

 Adjust until the impeller is in contact with the gland side casing liner and
reverse adjusting screw to move impeller 1.5mm (.06”) away from gland
side casing liner. Tighten the clamp bolts and spin the impeller by hand
to ensure ease of rotation.

10.5 SUCTION SIDE CASING ASSEMBLY

 Locate suction side casing (6) and set on flat surface with suction flange
side down. Shim the suction side casing so there will be at least a 6mm
(1/4”) gap between the suction flange face and flat surface. This will allow
the suction liner to stick through the suction flange properly.

 Fit suction side casing liner (4) inside suction side casing (6) by aligning
the studs of the suction side casing liner with the drilled holes of the
suction side casing. Push the studs through the holes and ensure the
outer dovetail flange of the suction side casing liner fits flat in the cast
recess of the suction side casing. Ensure that discharge flange of suction
side casing liner fits flat in machined recess of suction side casing. Install
washers (3) and nuts (9) on studs and tighten evenly to fully seat the
suction side casing liner in the suction side casing.

 Locate suction liner (5) and set on flat surface with studs facing up.

 Lubricate threads of wear ring screws (31) with anti-seize compound.

Install wear ring screws (31) in tapped holes of suction liner until they are

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 18
 flush with the underside of the metal insert in the suction liner. Turn
suction liner over to see this.

 With studs and screws in suction liner facing down, install wear ring (25) in
molded ribbed groove of suction liner. Push wear ring in suction liner until
fully seated and flat surface of wear ring is flush with raised ring of suction
liner.

 Lubricate tapered OD of suction liner and tapered ID of suction side

casing liner (4) with glycerin, soap, or an approved rubber lubricant.
Install suction liner with wear ring in suction side casing liner by fitting
tapered OD of suction liner with tapered ID of suction side casing liner.
Rotate suction liner until studs align with smaller drilled holes in suction
side casing (6) and wear ring screws (31) align with larger drilled holes in
suction side casing. Push suction liner into suction side casing liner by
hand. Fit washers (3) with nuts (9) on suction liner studs through suction
side casing and tighten evenly to fully seat the suction liner in the suction
side casing liner. The suction liner should be flush or slightly recessed
with the suction side casing liner at their mating surfaces after tightening
the nuts.

10.6 ASSEMBLY OF SUCTION SIDE CASING TO GLAND SIDE CASING

 Hoist suction side casing and install two casing roll pins (37) in drilled
holes of ribbed side of suction side casing (6) and drive through until they
stick through the machined side about 13mm (1/2”).

 Assemble suction side casing to gland side casing (1) by aligning the roll
pins on the suction side casing with the corresponding drilled holes on the
gland side casing. Drive roll pins part way into holes in gland side casing
and install casing bolts (8) with washers (7) in suction side casing. Install
washers (7) and nuts (13) on bolts (8) at gland side casing and tighten
evenly to bring suction side casing metal to metal with the gland side
casing. Drive the rolls pins in until they are flush with the cast surface of
the suction side casing.

10.7 IMPELLER ADJUSTMENT

 Loosen the housing clamp bolts on the bearing assembly.

 Use the adjusting screw to move the impeller axially towards the wear
ring.

 Adjust until the impeller is in contact with the wear ring and reverse
adjusting screw to move impeller 1.5mm (.06”) away from wear ring.
Tighten the clamp bolts and spin the impeller by hand to ensure ease of
rotation.

 Torque values for bearing assembly hold down clamp fasteners:


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 19
 Bearing Assembly Size Maximum Torque (Ft Lb/ Nm)
MMAA 60/80
MMA 100/135
MMB 170/231
MMC 250/340
MMD 500/675

11 MAINTENANCE

11.1 ROUTINE MAINTENANCE

 Routine maintenance is carried out to prolong the life of the pump parts
and to maintain pump performance to sustain the efficiency of the plant
operation. Critical maintenance is adjustment of impeller running
clearances.

11.2 WEAR RING ADJUSTMENT

 The Wear Ring (25) must be adjusted on initial start up (see Section 7 for
Start-Up instructions) and adjustment of this critical clearance should be
carried out a minimum of six times in the life of the pump. Typically every
four weeks, but may vary depending on the pumping application.

 The adjustment should be carried out when the pump is operating.

CAUTION: Over adjustment will give increased grinding and wear on
mating faces of Impeller and Wear Ring, with a corresponding
reduction in life. The Wear Ring Screws (31) should be tightened
clockwise two flats each, until contact / rubbing resistance is felt at all of
the Wear Ring Screws. This will occur when the Wear Ring contacts the
Impeller, and the Wear Ring Screws are evenly adjusted. Then loosen
each Wear Ring Screw by one half turn (or just enough that no rubbing is
felt). This will set the optimum clearance.

 The Wear Ring will typically outlast the life of the Suction Liner and it is not
commonly replaced.

11.3 SHAFT SEAL ADJUSTMENT

11.3.A CENTRIFUGAL SEAL

 The gland should be adjusted just tight enough that there is no leakage
while the pump is stopped. Charge the grease nipple on the expeller ring
until resistance at the grease gun lever is felt. Refer to section 5.3 for
grease recommendations.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 20
 11.3.B WATER FLUSH SEAL

 Gland packing should be adjusted, such that a small flow of gland water
along the shaft is obtained while the pump is running.
(For additional information refer to Section 5.4)

11.3.C MECHANICAL SEAL

 Please refer to the appendix containing details of the appropriate seal for
complete instructions.

11.4 BEARING LUBRICATION

 FLSmidth Krebs millMAX™ pump bearings are designed to provide years

of service before failure. The most common reason bearings do not reach
their design service life is because of contamination, not from the loads
they experience. One of the features designed into FLSmidth Krebs
millMAX™ bearing assemblies is the ability to grease the bearings without
danger of over greasing. The bearings are oriented on the shaft in such a
way as to allow the grease applied to pass through the bearing towards
the end covers and eventually to the outside of the bearing assembly.
The seals in the end covers are oriented to allow the grease to pass
through and retard the entrance of contaminants.

 Because of the many variations of speeds and environments bearings are

exposed to, it is difficult to provide a “cut and dried” lubrication schedule.
The table below will provide a suggestion as to the amount and frequency
of bearing lubrication. Please note that the use of this table does not
warrant neglecting the bearings completely. Judgment and experience
gained by observing the bearings frequently at the outset of operation,
taking careful note of conditions regarding temperature and cleanliness
should be the final determining factors in establishing routine lubrication
procedures.

BEARING
SIZE GREASE RPM
GRAM/(OZ) 200 300 400 600 800 1000 1200 1500 2000 2500 2900
MMAA 18/(0.6) 700 700 700 700 700 600 400
MMA 23/(0.8) 700 700 700 600 400 200
MMB 43/(1.5) 700 700 700 600 400 200
MMC 56/(2.0) 700 700 600 400 200
MMD 100/(3.5) 700 700 600 400 200

This chart is based on bearing operating temperatures of 70°C (160°F). The lubrication intervals should
be minimum weekly for operating temperatures greater than 70°C (160°F). Consult FLSmidth Krebs for
speeds greater than those listed in the chart above for synthetic grease lubricants.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 21
  There is no substitute for establishing base line readings after startup like
vibration and temperature and then monitoring them routinely for changes
in these readings to indicate a need for attention to the bearings.

 The grease nipples located on the bearing housing are for lubrication of
the bearings.

 The grease nipples fitted to the bearing housing end covers are for
lubrication of the lip seal and flinger area and provide a grease barrier to
prevent ingress of slurry and/or gland water to the bearings. These should
be greased daily so that clean grease exudes from the rim of the flinger. It
is not possible to over grease this area.

 For dirty environments that are commonly found in coal applications, or in

the event of an excessively leaking gland seal, the frequency of lubrication
should be halved no matter what the bearing operating temperature. The
impeller end lip seal should be greased twice a day. The thought should
always be “more is better than less”.

 Please see Section 5.3 for grease specifications and suggested brands.

 New bearing assemblies are pre-lubricated at the factory. Additional

grease at start-up should not be necessary.

12 PARTS REPLACEMENT

In general, most millMAX parts replacement procedures are straight forward and a
reverse of the installation. Please review assembly procedures before beginning work.

12.1 IMPELLER

 Removal of the old impeller can be done by reversing the instructions for
impeller installation, as found in the section on wet-end assembly.

 To allow the impeller to be unscrewed easily, the release collar must be

removed before the impeller is unscrewed. Release collars are only
available on MMB, MMC, and MMD power frames. Follow the following
steps.

Remove sealant in heads of socket head cap screws. Be sure to

achieve full engagement of the Allen wrench into the socket head.

Remove the three bolts holding the release collar together.

Using a soft metal rod or wood timber, strike the flat ledges on the
release collar segments to drive them out from between the sleeve
spacer (22) and flinger.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 22
 To replace release collar, use new grade 5 socket head cap screws.
DO NOT REUSE OLD SCREWS. The following is a list of socket head
cap screw sizes:
MMB 3/8”-16 x 1-3/4” long
MMC 3/8”-16 X 1-3/4” long
MMD ½”-13 x 2-1/4” long

There are punch marks on the flat face of two of the three segments of
the release collar. It is important to reassemble the release collar
segments with the punch marks together as shown in Figure 8. This
will ensure the segments fit properly.

Torque the socket head cap screws to 36Nm (26 ft lbs) for MMB and
MMC, 89Nm (65 ft lbs) for MMD. Apply Loctite 222 or equivalent to
screw threads prior to assembly. It may be necessary to install release
collar on shaft with screws loose before final torque is applied.

Fill the recess of the socket head cap screws with silicone sealant to
prevent moisture from contacting these fasteners and fouling the
threads.

13 TROUBLESHOOTING

13.1 DURING ASSEMBLY

Expeller ring/stuffing box jamming on shaft sleeve:

 Weight causing it to sag on shaft. Shim OD in gland side casing if
necessary to ensure air gap between shaft sleeve OD and ID of expeller
ring or lantern bush.

Gland side casing liner will not pull up tight to gland side casing:

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 23
  Fouling on expeller. Adjust bearing assembly away from gland side
casing.

Impeller jams before locking up to expeller/shaft sleeve:

 Fouling on gland side casing liner. Adjust bearing assembly towards
suction piping.

Impeller does not have equal gap, top and bottom, to gland side casing liner:
 Bearing assembly is out of alignment. Ensure bearing housing is fully
seated in pedestal saddles.

Suction side casing will not bolt up flush with gland side casing:
 Wear ring fouling on impeller. Adjust bearing assembly toward gland side
casing.

13.2 ON INITIAL START-UP

Drive belts slip/scream before pump gets up to speed:

 Belt tension incorrect.
 Insufficient power rating for the pump duty.
 Pump discharging into an empty system.

Pump locks solid on initial start up:

 Impeller was not tightened enough on assembly and has locked against
the gland side casing liner.
 Incorrect rotation has unscrewed impeller against wear ring.

Noise and/or sparks from gland follower:

 Gland follower tightened unevenly.

Excessive heat and/or smoke from gland:

 Gland follower too tight.

Belts turn over, or run off sheaves completely:

 Pulleys misaligned

Pump vibration:
 Partially blocked impeller.
 Loose hold down bolts.

13.3 DURING OPERATION

Insufficient or fluctuating discharge flow/pressure:

 Wear ring needs adjustment.
 Pump speed too slow.
 System head higher than design.
 Partial blockage in pipework.
 Air pocket in suction line caused by eccentric reducer the wrong way up.

Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 24
  Entrained air in slurry.
 Slurry viscosity higher than design.
 Sucking air through gland.
 Impeller badly worn.
 Impeller partially blocked.

Excessive discharge flow/pressure:

 Speed too high.
 System head lower than design.

High Power Consumption:

 Speed too high.
 System head lower than design.
 Slurry density higher than design.
 Incorrect wear ring adjustment.
 Incorrect impeller adjustment.

Excessive Gland Water Leakage:

 Too high gland water pressure.
 Gland Follower too loose.
 Packing needs to be replaced.
 Shaft sleeve badly worn.

Slurry Leakage From Expeller Ring:

 Suction head higher than design.
 Pump speed too low for effective expeller operation.
 Impeller too far from gland side casing liner.
 Expeller badly worn.
 Entrained air causing pressure fluctuations.

Slurry Leakage From Stuffing Box:

 Insufficient gland water pressure.
 Gland Follower too loose.
 Impeller too far from gland side casing liner.
 Worn gland parts.


Copyright FLSMIDTH KREBS millMAX™ MARCH (2010) 25