RECONDITIONING OF TITAN VERTICAL SPINDLE PUMPS by mikesanye

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									ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                  432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999            APPROVED 1999-05-18   PAGE 1 OF 10

       CONTENTS                                                       PAGE

1.0    SCOPE                                                            2

2.0    TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER           2

3.0    DEFINITIONS                                                      2

4.0    REQUIREMENTS                                                     2

4.1    Records                                                          2
4.2    Pumps                                                            3
4.3    Shafts                                                           3
4.4    Casings                                                          3
4.5    Suspension frame                                                 5
4.6    Bearing pedestal                                                 5
4.7    Upper and lower screens                                          5
4.8    Motor mount                                                      5
4.9    Coupling                                                         5
4.10   Motor                                                            5
4.11   Impeller                                                         5
4.12   Bearings                                                         6
4.13   Seals and flingers                                               6
4.14   Bolts, nuts and fasteners                                        6
4.15   Lubricant                                                        6
4.16   Corrosion protection                                             6

5.0    QUALITY ASSURANCE PROVISIONS                                     6

6.0    INSPECTION AND TEST METHODS                                      6

6.1    Operational proof test                                           6

7.0    MARKING AND PACKING                                              6

7.1    Marking                                                          6
7.2    Packing                                                          7

APPENDIX A       : RELATED DOCUMENTS                                    8

APPENDIX B       : RECORD OF AMENDMENTS                                 9

APPENDIX C       : APPROVED LIST OF BEARING MANUFACTURERS               10
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                       432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                         APPROVED 1999-05-18           PAGE 2 OF 10

1.0    SCOPE

       This specification details the requirements for the reconditioning of “Titan ” vertical spindle
       pumps 50 mm, 65 mm, 80 mm and 100 mm discharge.

2.0    TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

       The following requirements shall be specified on every invitation to tender, contract or order.

          Title, number, date and issue of this specification.

          Pump size.

          Pump number.

3.0    DEFINITIONS

       For the purpose of this specification, the following definitions shall apply.

       APPROVED         :    Approved by the Engineer in writing

       ENGINEER         :    The Consulting Mechanical and Electrical Engineer of AngloGold Ashanti or
                             the appointed representative

       SABS             :    South African Bureau of Standards

       OEM              :    Original Equipment Manufacturer

       P/Q DIAGRAM :         Pressure / flow curve

       The following terms are defined in the General Conditions of Contract:

       AngloGold Ashanti, Company, Contractor.

4.0    REQUIREMENTS

       The pump shall be restored to the original condition and performance to comply with the OEM’s
       P/Q diagram.

       The requirements of the Mineral Act. No. 50 of 1991 shall apply.

4.1    Records

       The following details shall be recorded and retained for every unit:

       *       Serial number
       *       Size
       *       Performance

       Records shall be kept for a minimum period of 1 year.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                        432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                          APPROVED 1999-05-18           PAGE 3 OF 10

4.2     Pump

        The pump shall be disassembled and fully cleaned of all foreign matter. Care shall be taken not
        to damage machined surfaces.

4.3     Shafts

4.3.1   Shafts: shall comply with the tolerances specified by the OEM. Shafts worn beyond the
        machining limits shall be cause for rejection.

4.3.2   Where replacement shafts: are manufactured by the Contractor, these shall be manufactured
        from steel which complies with the requirements of BS 970 Grade 080M40.

4.3.3   All contact surfaces: for hub connections, bearings, seals and couplings shall be machined
        round to a surface texture not rougher than 1.6 mm Ra. Undercuts, reliefs and grooves are not
        permitted.

4.3.4   The shafts: shall be of uniform, nominal cross-section. Reductions in shaft diameter shall be
        permitted only where the impeller landing or the bore of the coupling is smaller than the journal
        diameter of the shaft.

4.3.5   The shaft reduction diameter step: shall have a root radius equal to or greater than 0.3 of the
        minor diameter of the shaft. All external corners shall be chamfered 3 mm at 45.

4.3.6   Repairs of shafts by electric arc spray: shall be carried out with Approval.

4.3.7   Keys and keyways: shall comply with the requirements of BS 4235, Part 1. Keys shall not
        protrude beyond the outer hub face. Keys and keyways for shaft extensions beyond the bearing
        shall be provided to suit the attachments required for the application.

4.4     Casings

        Casings worn outside the tolerances specified by the OEM shall be replaced with casings
        obtained from the OEM.

4.4.1   Suitability of casings for lining: it is the responsibility of the contractor to ensure suitability of
        the casing for lining. Distortion of more than 1 mm when measured over the top mating surface
        will be reason for rejection. This measurement shall be taken before application of new lining
        but after removal of old lining.

4.4.2   Removal of old lining: lining shall be removed by burning off or mechanical means.

4.4.3   Surface preparation:

4.4.3.1 All surfaces to be lined: shall be abrasive blast cleaned to a grade SA 2½ finish in accordance
        with the requirements of SABS 064.

4.4.3.2 Blast profile: shall be 35 micron minimum when measured in accordance with SABS method
        772.

4.4.3.3 Compressed air: used for blast cleaning shall be free of oil and moisture content.

4.4.3.4 The surface to be bonded: shall shall be free of oil, grease or dust.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                     432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                        APPROVED 1999-05-18          PAGE 4 OF 10

4.4.4   Lining:

4.4.4.1 Within four hours of blast cleaning: being conducted the surfaces to be lined shall receive a
        coat of polyether based hydrolytically stable bonding agent applied in accordance with the
        manufacturer’s instructions.

4.4.4.2 All surfaces to be lined: shall receive a lining of PTMG elastomeric polyurethane heat cured
        with MOCA.

        The casing shall be heated to a suitable temperature maintained for 12 hours at that
        temperature until gelation of the lining has been achieved.

        The thickness shall be specified on the OEM drawings when measured at any point of the lining
        in accordance with the method as specified in SABS Method 141.

4.4.4.3 The cured polyurethane elastomer: shall have a shore A hardness of 88-93 when measured
        in accordance with the method specified in ASTM D2240.

4.4.4.4 The raw material manufacturer: shall provide certification with each batch that when cured in
        accordance with their instructions the cured properties of the polyurethane elastomer shall be as
        specified in Table 1.

                                                TABLE 1

                             PROPERTIES OF CURED POLYURETHANE

PROPERTY                            VALUE                                TEST METHOD

Specific gravity at 20°C            1.14                                 ASTM Method D792
Hardness Shore A                    88 to 93                             ASTM D2240
100% Modulus kPa                    6500 to 7300                         DIN 53504
300% Modulus kPa                    13000 to 14500                       DIN 53504
Tensile strength kPa                305000 to 345000                     DIN 53504 Dumbell S2
Elongation (%)                      410 to 450                           DIN 53504
Rebound relilience (%)              40 to 48                             Din 53512
Tear strength (kN/m)                12 to 14                             ASTM D624

4.4.5   Testing

4.4.5.1 Shore hardness: when tested in accordance with the method specified in Table 1 the shore
        hardness shall be in the specified range.

4.4.5.2 High voltage sparking EID detection: when tested in accordance with the method specified in
        SABS 1217 there shall be no electrical insulation defects.

4.4.5.3 Bond strength: when specified by the Purchaser bond strength test shall be conducted prior to
        start of the contract.

        Test samples shall consist of pieces of substrate similar to the casings to be lined to which has
        been applied polyurethane in accordance with Clause 4.3 of this specification.

        Bond strength shall be not less than 10 kN/mm2 when measured in accordance with method B
        of BS 903 Part A21.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                  432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                      APPROVED 1999-05-18         PAGE 5 OF 10

4.5    Suspension frame

       The suspension frame top spigot if found to exceed the limits specified by the OEM shall be
       repaired by welding and re-machined to the sized specified by the OEM.

       Out of squareness of greater than 0.5 mm to the vertical axis shall not be allowed

       A maximum differential of 0.1 mm when measured over the length at any point on the front end
       of the spigot shall be allowed.

4.6    Bearing pedestal

       The bearing pedestal spigots when found to exceed the limits specified by the OEM shall be
       repaired by welding and re-machining. The Contractor shall be in possession of Approved
       welding procedures for the process.

       Out of squareness to the vertical axis of more than 0.5 mm shall not be allowed.

       The maximum differential on any area on the front face of the flanges or spigots shall not exceed
       0.1 mm.

       Repairs to bearing landing shall be done by using cold process metal spraying.

4.7    Upper and lower screens

       Where upper and lower screens are found to be worn beyond the levels specified by the OEM,
       the units shall be replaced.

4.8    Motor mount

       Where wear on spigots are found to exceed the limits specified by the OEM it shall be repaired
       by welding and re-machining. Out of squareness of more than 0.5 mm shall not be allowed

       The maximum differential when measured on any area of the flanges or spigots shall not exceed
       0.1 mm. Welding shall be done in accordance with BS 5135.

4.9    Coupling

       Where couplings are found to be worn or loose on the shaft they shall be replaced with an
       Approved make and type

       The rubber element shall be replaced where visual wear or damage is evident.

       Note: Taper locks shall not be used.

4.10   Motor

       The motor shall be reconditioned in accordance with requirements of AngloGold Ashanti
       specification 538/7.

4.11   Impeller

       Worn impellers shall be replaced by an impeller obtained from the OEM.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                   432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                        APPROVED 1999-05-18        PAGE 6 OF 10

4.12   Bearings

       Replacement of bearings shall be mandatory. Bearings shall be replaced with C3 clearance
       bearings. Journal and housing machining tolerances shall be as specified by the bearing
       manufacturer.

4.13   Seals and flingers

       Replacements of seals shall be mandatory. Seals shall be replaced with seals specified by the
       OEM. Flingers shall be replaced with those obtained from the OEM.

4.14   Bolts, nuts and fasteners

       Replacement of bolts and fasteners shall be mandatory. On the suction inlet, bolts and nuts
       shall be replaced with bolts and nuts manufactured from stainless steel to BS 970 Grade
       431S29.

4.15   Lubrication

       The grease cavity shall be filled with grease which complies with the requirements of AngloGold
       Ashanti specification 166/0 and 166/14.

4.16   Corrosion protection

       Corrosion protection shall be in accordance with the requirements of AngloGold Ashanti
       specification 164/50 and CPS 252

5.0    QUALITY ASSURANCE PROVISIONS

       AngloGold Ashanti QSP 101 shall apply.

6.0    TEST AND INSPECTION METHODS

6.1    Operational proof test

       The following proof test shall be conducted on all reconditioned pumps:

       Operate the pump at designed operating speed for a period of 5 minutes on a test rig able to
       measure pressure and flow.

       After this period the following shall be recorded:

       Flow, head and motor amps, at full flow, half flow and zero flow (closed valve condition). The
       unit shall then be run outside the test rig (dry condition) and the amps recorded. The data shall
       be plotted on the OEM performance curve and supplied with every unit.

7.0    PACKING AND MARKING

7.1    Packing

       The method of packing shall protect the equipment against damage and adverse climatic
       conditions during transportation and storage.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                 432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                      APPROVED 1999-05-18        PAGE 7 OF 10

7.2    Marking

       The following information shall be hard stamped on a suitable and protected position on the
       pump:

       *       Serial number
       *       Mine order number
       *       Contractor’s number or logo
       *       Date of reconditioning

       Any Company identification marks shall be transferred if necessary.
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                                                      432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999                        APPROVED 1999-05-18           PAGE 8 OF 10

APPENDIX A : RELATED DOCUMENTS


AngloGold Ashanti Specification 164/50       :    Corrosion protection of steelwork with coatings

AngloGold Ashanti Specification 166/0        :    Lubricants – General requirements

AngloGold Ashanti Specification 166/14       :    Lubricants – Specific requirements for general purpose
                                                  greases

AngloGold Ashanti QSP 101                    :    Quality requirements for minor products

CPS 252                                      :    Plant maintenance patch prime (Polyurethane finish)

The Minerals Act, No. 50 of 1991.

The latest issues of the following documents shall be deemed to form part of this specification.

ASTM D624                               :    Test method of rubber property – tear resistance

ASTM D792                               :    Test method for specific gravity and density of plastics by
                                             displacement

ASTM D2240                              :    Test method for rubber property Durometer hardness

BS 903 Part A21                         :    Methods of testing vulcanized rubber. Determination of
                                             rubber to metal bond strength

DIN 53504                               :    Testing of vulcanized rubber. Determination of tensile
                                             strength at break, elongation at break and stress values in a
                                             tensile test

DIN 53512                               :    Testing of rubber. Determination of rebound resilience

SABS ISO 9000                           :    Quality management systems

SABS 1217                               :    The production of painted and powder coated steel pipes

SABS 064                                :    Preparation of steel surfaces for coating

SABS Test Method 141                    :    Dry film thickness of paints by means of a magnetic flux
                                             type gauge

SABS Test Methods 772                   :    Profile of blast-cleaned steel surface for painting
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                          432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999    APPROVED 1999-05-18   PAGE 9 OF 10

APPENDIX B : RECORD OF AMENDMENTS
ANGLOGOLD ASHANTI SPECIFICATION

RECONDITIONING OF “TITAN” VERTICAL SPINDLE
PUMPS

                                                            432/4 ISSUE 2
COPYRIGHT ANGLOGOLD ASHANTI 1999      APPROVED 1999-05-18   PAGE 10 OF 10

APPENDIX C : APPROVED LIST OF BEARING MANUFACTURERS

FAG
KYO
NACHI
NSK
NTN
PHOENIX
RHP
SKF
SNR
STEYR
TIMKEN

								
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