manual de celda de flotacion

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

EIMCO® 160M3 FLOTATION CELL BUYOUTS

Serial No.: CSP0000671-03 A thru C

For

Cerro Verde Arequipa, Peru

Sociedad Minera Cerro Verde Peru

Purchase Order No.: 4-0706

FLSmidth Salt Lake City, Inc. Order No.: CSP0000671-03

Final versions of all supporting documents and erection drawings should be annexed with the manual

DW – DATA ACCEPTED FOR INFORMATION ONLY / WITH COMMENTS

Authorization to proceed does not relieve Contractor/Supplier of its responsibility or liability under the Contract and or Purchase Order.

®

By Biswaranjan Dattabhaumik at 2:57 pm, 21 May 2013

Confidential and Proprietary Property of

FLSmidth Salt Lake City Inc.

For Confidential Use Only

Not For Circulation, Distribution Or Reproduction

Without Prior Permission In Writing

© FLSmidth A/S

All Rights Reserved

Wemco® 160m3 Flotation Cells Installation, Operation and Maintenance Manual

Cerro Verde – Sociedad Minera - Peru

Created by: Melanie Henderson Approved by: Nate Taylor FLSmidth, 23-April-2013 Document No. CSP0000671-03

Contents 2

Revision History The following table summarizes the revision history of this manual.

Revision Summary of changes Author Revision date

1 Initial Release- Instruction Manual

(FLS Salt Lake Word Format)

Melanie Henderson

(Nate Taylor)

15-April-2013

(23-April-2013)

Wemco® 160m3 Flotation Cells Document No. CSP0000671-03

Contents 4

Contents

Chapter 1: General Information 8

1.1 Foreword ..............................................................................................8

1.2 Receiving and Inspection .........................................................................9

1.3 Packing Boxes and Covers .......................................................................9

1.4 Shipping Braces and Bars ........................................................................9

1.5 Maintenance and Start-up Services ...........................................................9

1.6 Parts and Repair Orders ..........................................................................9

1.7 Storage .............................................................................................. 10

1.7.1 Storage of Rubber Products ................................................... 10

1.8 Special Instructions to Equipment Installers ............................................. 11

1.9 Original Equipment Manufacturer’s Instruction Manuals ............................. 11

1.9.1 Minor Discrepancies ............................................................. 12

1.9.2 Major Discrepancies ............................................................. 12

1.10 Field Painting and Welding ..................................................................... 12

1.11 Required Special Tools, Materials and Supplies (Not by FLSmidth) ............... 12

1.12 Offices ................................................................................................ 12

Chapter 2: Safety 15

2.1 Hearing Protection ............................................................................... 18

2.2 Safety Signs ........................................................................................ 19

2.2.1 Area Safety Signs ................................................................ 19

2.2.2 Equipment Safety Signs ........................................................ 20

2.3 Environmental Management Cautions ...................................................... 20

2.3.1 Paint .................................................................................. 20

2.3.2 Cleaning Agents .................................................................. 21

2.3.3 Cleaning Materials ............................................................... 21

2.3.4 Grease ............................................................................... 21

2.3.5 Lubricating Oil ..................................................................... 21

2.3.6 Hydraulic Oil ....................................................................... 21

2.3.7 Process Samples .................................................................. 22

2.3.8 Used Parts and Materials ....................................................... 22

2.3.9 Installation and Maintenance Equipment ................................. 22


Contents 5

Chapter 3: Installation 23

3.1 Tank Support Structure ......................................................................... 23

3.2 Tank and Component Lifting .................................................................. 23

3.3 Tank Installation .................................................................................. 24

3.4 Install the Velocity Cone, Draft Tube, False Floor Plates and Manway Door .................................................................................................. 27

3.5 Install the Baffles, Radial Launders, and Weirs ......................................... 29

3.6 Install the Mechanism Assembly ............................................................. 31

3.6.1 Install the Mechanism Assembly in the Tank ............................ 35

3.6.2 Align Bearing Housing and Shaft Assembly .............................. 35

3.6.3 Check Rotor for Concentricity with Draft Tube .......................... 36

3.6.4 Install the Split Collar ........................................................... 37

3.6.5 Check the Motor Shaft for Plumb ............................................ 38

3.6.6 Belt Guard, Sheave and V-Belt Installation .............................. 38

3.7 Install Level Sensor Assembly ................................................................ 40

3.8 Install the Froth Sensor Assembly .......................................................... 42

3.9 Install the Electrical Power and Controls .................................................. 43

3.9.1 Electrical controls ................................................................ 43

3.10 Cable Trays, Grating, Walkway Assemblies and Stairway Assemblies Installation .......................................................................................... 44

3.11 Final Inspection before Start-Up ............................................................. 44

3.12 Mechanical Check ................................................................................. 45

3.12.1 Final Mechanical Check ......................................................... 45

3.12.2 Arrangements for Service ..................................................... 45

Chapter 4: Lubrication 46

4.1 Flotation Cell Drive ............................................................................... 46

4.2 Bearing Housing and Shaft Assembly ...................................................... 46

4.3 Lubrication Procedures and Schedule ...................................................... 46

4.4 Lubrication Schedule ............................................................................ 49

Chapter 5: Maintenance 50

5.1 Maintenance and Operation Warning ....................................................... 50

5.2 Before Operation, Maintenance or Repair of this Equipment ........................ 51

5.3 General Maintenance ............................................................................ 51

5.4 General Cleaning ................................................................................. 51


Contents 6

5.5 Drive V Belt Tension ............................................................................. 52

5.6 Lubrication .......................................................................................... 53

5.7 Air Control Assembly ............................................................................ 53

5.8 Star Rotor and Split Collar ..................................................................... 54

5.9 Hood Sectors ....................................................................................... 54

5.10 Disperser ............................................................................................ 54

5.11 Standpipe and Crowder Assembly ........................................................... 54

5.12 Tanks, Feed box and Connection/Discharge Boxes .................................... 54

5.13 Flotation Level Control Assembly ............................................................ 55

5.14 Dart Valve and Actuators ...................................................................... 55

5.15 Fasteners ............................................................................................ 56

5.16 Removal of Complete Mechanism ........................................................... 56

5.17 Reinstallation of Complete Mechanism ..................................................... 57

5.18 Component Removal and Installation ...................................................... 58

5.18.1 Removal by Parts................................................................. 58

5.18.2 Motor ................................................................................. 60

5.18.3 Air Inlet Assembly ............................................................... 61

5.18.4 Hood Sectors ...................................................................... 61

5.18.5 Disperser ............................................................................ 62

5.18.6 Standpipe and Crowder ........................................................ 63

5.18.7 Star Rotor .......................................................................... 63

5.18.8 Draft Tube Split Collar: ......................................................... 64

5.18.9 Belt Guard and Sheaves ....................................................... 64

5.18.10 Bearing Housing and Shaft Assembly ...................................... 65

5.19 Dart Valve Maintenance ........................................................................ 66

5.19.1 Dart Valve Replacement ....................................................... 66

5.19.2 Dart Valve Seat Replacement ................................................ 68

5.19.3 Stuffing Box Packing Replacement.......................................... 69

5.20 Fastener Torque Specifications ............................................................... 71

Chapter 6: Operation 73

6.1 Flotation ............................................................................................. 73

6.2 WEMCO® Flotation Machines ................................................................. 73

6.3 Level Controls ..................................................................................... 75

6.3.1 Dart Valves ......................................................................... 75

6.4 Start-up and Operation ......................................................................... 75

6.5 Shutdown ........................................................................................... 77


Contents 7

6.5.1 Planned Shutdown (for cell inspection or maintenance) ............. 77

6.5.2 Unplanned Shutdown ........................................................... 77

Chapter 7: Troubleshooting 78

Chapter 8: Final Mechanical Checklist 85

8.1 SERIAL NUMBER: CSP0000671-03A ..................................................... 85

8.2 SERIAL NUMBER: CSP0000671-03B ..................................................... 90

8.3 SERIAL NUMBER: CSP0000671-03C ..................................................... 95

Chapter 9: Appendices 100

9.1 Drawing List ...................................................................................... 100

Chapter 1: General Information

1.1 Foreword In keeping with the FLSmidth commitment to provide the latest technology and improvements in its products, FLSmidth is also committed to providing the highest level of service and helping you solve your process problems.

Accordingly, if FLSmidth can help in the operation of your flotation equipment, feel free to contact us at (801) 871-7000, FAX (801) 871-7001. Also, if you have any suggestions or comments that will help us serve you better, please forward them to us.

To ensure you receive the full benefits of proper installation, maintenance and operation of the WEMCO® Flotation Machines, we ask you to thoroughly read and familiarize yourself with the instructions in this manual. Refer to the Table of Contents at the front of the manual.

The equipment, including the accessory equipment furnished but not built by FLSmidth, must be stored, installed, operated, and maintained according to the manufacturer's instructions to ensure warranty coverage.

The instructions in this manual are based on information available at the time of issue of this manual. The right is reserved to make subsequent changes to the instructions without obligation to replace existing copies.

Documents, drawings, technical manuals and all other information contained in this manual, provided in conjunction with the purchase of FLSmidth products and services, are the property of FLSmidth and are confidential and may not be made public or copied.

FLSmidth will not furnish editable electronic copies of any data and/or drawings at any time.

FLSmidth accepts no liability whatsoever for unauthorized changes and/or alterations to the data provided.

English is the governing language. When manuals are provided in both English and any language other than English, THE NON-ENGLISH TRANSLATION IS PROVIDED ONLY AS A CONVENIENCE. FLSmidth shall not be liable for damages caused by errors in translation. The English translation will govern in case of minor discrepancies. In the event of major discrepancies, notify your FLSmidth representative immediately. Refer to the Offices page in this manual for applicable address and telephone number.


Contents 9

1.2 Receiving and Inspection Although all possible precautions are taken to protect the equipment against damage or losses during shipment, check all items against the packing list before accepting delivery. In case of shortages or evidence of physical damage, immediately notify the carrier.

Notify FLSmidth within 7 days (maximum) in case of shortages or discrepancies, according to the packing list. If not notified, FLSmidth cannot be responsible for replacing those items. Keep a record of all claims and correspondence. Photographs are recommended.

1.3 Packing Boxes and Covers Do not remove protective covers unless there are indications of damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents. The parts should be packaged and stored in a safe place. Examine all packing boxes, wrappings and covers for items attached to them, especially if the packaging materials are to be discarded. Refer to the Storage Instructions.

1.4 Shipping Braces and Bars Support braces, bars, banding, etc. used for shipping should not be removed until necessary by equipment installation or operation. Shipping braces are normally, but not always, marked or painted to show they are only temporary shipping supports.

1.5 Maintenance and Start-up Services Experienced FLSmidth engineers and service personnel are available to advise in the operation and maintenance of this equipment. They offer the benefits of their technical know-how and firsthand knowledge of the equipment, plus the backing of FLSmidth’ entire engineering and research facilities.

They can instruct on proper operating and maintenance, advise on trouble shooting, or solve your process problems. If you want such assistance, contact us at (801) 871-7000 [USA] or FAX (801) 871-7001 or call your FLSmidth representative, referring to the Offices page.

1.6 Parts and Repair Orders To assure you receive the right replacement parts for your equipment and avoid delay, it is important to give the following information with each order:

Size and type of unit: These are found on the cover page of the manual, on the Top Level drawing and in the Parts List.

Customer SO number: This is found on the Top Level drawing, the Parts List Index and throughout the Parts List.

Part number and description: These are listed in the Parts List for each item.


Contents 10

Send your parts orders to FLSmidth, referring to the offices page in this manual.

1.7 Storage When the equipment is not to be installed immediately, proper storage is important to ensure warranty protection.

Store motors, if shipped separately, in a dry, ventilated building if possible. Refer to the Motor Manufacturer's Instructions. If stored outdoors, cover with a tarpaulin to protect against rain, moisture and dust.

Store the drive mechanisms by elevating them on blocks, etc., above the ground level and cover with tarpaulins.

A suitable corrosion inhibitive agent should be applied to all surfaces subject to rust or corrosion, if the storage will be more than 2 months or under adverse conditions.

Check for the formation of rust, especially on bright or unpainted steel surfaces. Remove rust or corrosion and apply a suitable corrosion inhibitor.

Refer to Storage of Rubber Products below.

1.7.1 Storage of Rubber Products Rubber products in storage can be adversely affected by the following: temperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids and fumes, insects and rodents, and radiation.

Rubber parts should be protected from the sun and from physical damage by objects that can cut or tear.

The warehousing area should be relatively cool, dark, and free from dampness and mildew. All rubber products should be stored on a first-in, first-out basis since even under these conditions an unusual length of time in storage can result in the deterioration of certain products.

Rubber products should not be stored under conditions of high or low humidity.

The ideal storage temperature for rubber products is 50 to 70°F (10 to 21°C) with a maximum limit of 100°F (38°C). If stored below 32°F (0°C), some products may become stiff and should be warmed before being placed in service. Rubber products should not be stored near sources of heat, such as radiators and base heaters.

To protect against the adverse effects of ozone, rubber products should not be stored near electrical equipment that may generate ozone and should not be stored for any lengthy period in geographical areas of known high ozone concentrations. Exposure to direct and reflected sunlight should also be avoided.

Whenever feasible, rubber products should be stored in their original shipping containers, especially when such containers are wooden crates or cardboard cartons, since this will


Contents 11

provide protection against the deteriorating effects of oils, solvents, and corrosive liquids and will also afford some protection against ozone and sunlight.

Since certain rodents and insects thrive on rubber products, adequate protection should be provided against them.

1.8 Special Instructions to Equipment Installers FLSmidth does not anticipate problems with the erection of this equipment. However, due to the nature of fabricated steel equipment, the erector may require a certain amount of field fit-up and adapting work. This is considered to be a normal part of erection, as well as the use of such tools as come-alongs, welding equipment, cutting torches, and drift pins. In case of such problems, the following will apply:

The AISC "Code of Standard Practice", latest edition, specifically states under "Correction of Errors" that cutting, reaming and use of drift pins are a part of standard erection practice:

"Normal erection operations include the correction of minor misfits by moderate amounts of reaming, chipping, welding or cutting, and the drawing of elements into line through the use of drift pins. Errors that cannot be corrected by the foregoing means or that require major changes in member configuration are reported immediately to the owner and fabricator by the erector. This is done in order to enable whoever is responsible either to correct the error or to approve the most efficient and economic method of correction to be used by others."

Should a problem develop because of manufacturing or engineering errors, FLSmidth will not accept back charges, unless they are authorized in advance and in writing by your FLSmidth Project Manager. Before corrective work is started, the erector must obtain an FLSmidth Field Work Order that must include a cost limitation. Payment may be refused for corrective work that is done without the above authorization.

Authorized charges will be paid only on the basis of standard direct field labor hours, material, and variable overhead. Other charges will not be allowed.

Drawings and erection or installation instructions must be followed. The drawings will govern in case of minor discrepancies. In the event of major discrepancies, notify your FLSmidth representative immediately, referring to the Table of Contents for the location of the Offices page.

Grouting of tanks, feed boxes, connection and discharge boxes, if required, is not by FLSmidth. Use non-shrinking type grout (not by FLSmidth).

1.9 Original Equipment Manufacturer’s Instruction Manuals Whenever the installation, lubrication, maintenance, or operation of an accessory piece of equipment, which has been furnished by FLSmidth but was manufactured by a third party, is discussed in the FLSmidth instruction manual, this information is provided only as a


Contents 12

guideline and that information must be verified by consulting the manufacturer’s instruction manuals, which are the ruling documents for the accessory equipment.

1.9.1 Minor Discrepancies The manufacturer’s instructions will govern in case of minor discrepancies.

1.9.2 Major Discrepancies In the event of major discrepancies, notify your FLSmidth representative immediately.

Refer to the Offices page for contact information (see Table of Contents).

1.10 Field Painting and Welding If a protective coating (paint, rubber, etc.) is to be field applied to the mechanism, it may need to be applied to some parts before they are installed. Parts that must be coated before installation are those that would be inaccessible after installation. Hold back paint 3” from all field welds. Study Assembly and Erection drawings carefully and determine field welded areas in question before painting.

WARNING: The fumes given off during welding and cutting can be injurious to the operator's health. Some fumes, such as those produced when working with Zinc, Cadmium and painted surfaces can be toxic.

1.11 Required Special Tools, Materials and Supplies (Not by FLSmidth)

Belt Tension Measurement Tool Transit Torque Wrench Straight Edge Machinist Level “Never Seize” Type Compound Welding Equipment Lifting Equipment Non-Shrinking Type Grout Shims

1.12 Offices FLSmidth

FLSmidth Salt Lake City Inc. 7158 South FLSmidth Drive Midvale, Utah 84047-5559 Telephone: 801-871-7000 Toll Free: 1-800-826-6461 Facsimile: 801-871-7001


Contents 13

After completion of the contract, all service and spare parts will be supported by the Region Headquarters.

NOTE: All telephone/facsimile numbers are preceded by a country code (e.g. Mexico 52 +).


Contents 14

North American Region Headquarters:

FLSmidth

FLSmidth Salt Lake City Inc.

7158 South FLSmidth Drive

Midvale, Utah 84047-5559, U.S.A.

Telephone: 1 + 801-871-7000

Toll Free: 1 + 800-826-6461

Facsimile: 1 + 801-871-7001

Europe, Africa, Mid-East Region Headquarters:

FLSmidth (UK) Ltd.

11 Mitchell Court

Castle Mound Way

Central Park

Rugby, Warwickshire

CV23 0UY

United Kingdom

Telephone: +44 (0) 1788 555777

Facsimile: +44 (0) 1788 560738

FLSmidth S.A. de C.V

San Alberto 406

Col. Residencial Santa Barbara

San Pedro Garza Garcia · N.L, 66266 · Mexico

Telephone: +52 81 1001-9500

Facsimile: +52 81 1001-9545

FLSmidth (Pty.) Ltd.

Cnr Constantia Boulevard & Albert Schweitzer Streets

Constantia Kloof, Roodepoort, 1709,

Gauteng, South Africa

Telephone: +27 (0)10-210-4000

Facsimile: +27 (0)10-210-4050

Latin American Region Headquarters:

FLSmidth S.A.

Nueva de Lyon 072 – Office 1102

Providencia, Santiago – 751-0078 Chile

Telephone: 56 + 2-290-0000

Facsimile: 56 + 2-334-3949

Asia-Pacific Region Headquarters:

FLSmidth Pty. Ltd.

5 Comserv Close

West Gosford. NSW 2250, Australia

Telephone: + 61(0) 2-4320-4700

Facsimile: + 61(0) 2-4320-4777

FLSmidth Ltda.

Divisão Minerals

Rua Dolles. 264- 2º Andar

CEP-18.116-710-Jardim Clarice II- Votorantim - São Paulo- Brasil

Telephone: 55+15-3416-7400

Facsimile: 55+15-3416-7599

FLSmidth Beijing Ltd.

7F, Tower A, Ping An International Financial Center

No. 1-3 Xinyuan South Road

Chaoyang District

100004 Beijing

Peoples Republic Of China

Telephone: 86+10-8468-9100

Facsimile: 86+10-8468-9299

Canada Region Headquarters:

FLSmidth Ltd.

174 West Street South

Orillia, Ontario L3V 6L4 Canada

Telephone: (705) 325-6181

Facsimile: (705) 325-3363


Contents 15

Chapter 2: Safety As with any other mechanical equipment, there are safety concerns associated with the installation, operation and maintenance of FLSmidth supplied equipment. It is absolutely essential that operators, maintenance personnel, and supervisors be instructed in safe working practices. All personnel should observe the warnings on the equipment; in this instruction manual; and know the potential hazards and how to avoid them.

Only personnel who have been trained in the safety procedures for this equipment should be allowed around or in the area of the FLSmidth equipment or the accessory equipment furnished by FLSmidth.

No personnel, authorized or unauthorized, should depend wholly on safety devices to prevent accidents. Safety features and devices are meant only to supplement proper, careful, and safe practices on the part of the individual.

WARNINGS and CAUTIONS are included throughout this manual for your safety. Read and understand them before installing, maintaining or operating this equipment. Also, refer to the appropriate OSHA safety requirements for additional information concerning personnel working on or around this equipment.

WARNING: Understanding and experience with this equipment is essential for the safe operation and maintenance of the equipment. In case of a question on how to safely proceed, contact the appropriate FLSmidth regional office immediately.

WARNING: If the safety procedures given in this manual are compromised or ignored, severe personal injury or death may occur. Safety practices accepted by the industry, as well as those dictated by the responsible regulatory agencies must be followed.

WARNING: The fumes given off during welding and cutting can be injurious to the operator's health. Some fumes, such as those produced when working with Zinc, Cadmium or painted surfaces can be toxic.


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WARNING: To prevent injuries to yourself or others, use extreme care when working near rotating or other moving parts. Any individual entering the area of this equipment must wear adequate safety equipment such as safety glasses, safety shoes, hard hat, hearing protection, etc.. Loose fitting clothing, uncovered long hair, or jewelry must not be worn when working around rotating or moving equipment.

WARNING: Keep foreign objects, hands, etc. away from moving parts (chains, sprockets, belts, sheaves, etc.). Do not operate this equipment if guards have been removed or are damaged. All guards and safety devices must be properly installed and functional before operating this equipment.

WARNING: Disable power from electrical equipment using a manual breaker or a disconnect switch before starting any work or maintenance on the equipment. Lock and tag the disconnect switch so it cannot be closed.

WARNING: Only trained, competent personnel should adjust electrical equipment.

WARNING: No electrical safety function should ever be jumped or bypassed. Control panel doors must be closed at all times. Never use oversize fuses, buss bars, or heaters. Motor drives and accessories should be connected to an electrical ground such as an underground water piping system, the frame of a building, or etc.

WARNING: Where corrosive or dangerous chemicals are handled, or there is possible operator exposure to these dangerous chemicals, anyone entering the area of the equipment must be wearing adequate safety equipment such as full face and/or eye protection, rubber gloves, safety shoes, hard hats, protective clothing, and respiratory masks.

WARNING: Hydraulic oil is an eye irritant, a skin irritant, and is toxic if ingested. Eye protection, skin protection, respiratory masks, etc, must be used during maintenance and/or repair of hydraulic systems.


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WARNING: To prevent injuries to yourself or others, use extreme care when lifting structural components. Also, anyone entering the area of this equipment must be wearing adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.

WARNING: All rigging and lifting must be done by experienced personnel who are fully trained in the proper procedures for rigging and lifting of large components. Verify the rigging and hoist equipment are of adequate capacity. Confirm the equipment being lifted or the lifting equipment cannot come into contact with overhead electrical cables, etc.

WARNING: Stand clear as the equipment is lifted.


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2.1 Hearing Protection

WARNING: Use hearing protection anytime there is exposure to noise.

Noise is a deceptive hazard. Workers can be exposed to considerable amounts of noise and not be aware that they may have suffered permanent injury. Noise intensity exceeding an average of 90 decibels over an 8-hour period can cause hearing loss. This intensity exists in most industrial and processing plants. Noise also increases a worker’s fatigue and stress level. It presents additional hazards when the worker is unable to clearly hear instructions or warning signals.

The selection and proper use of adequate hearing protection should be taken seriously by personnel operating and maintaining this equipment.

Know the types of hearing protection required in your work area. The two basic types of hearing protection are earplugs and ear muffs. In extreme noise-exposure areas, both earplugs and ear muffs are recommended.

Always use hearing protection in areas where it is specifically required by plant procedures for the work environment.

Select the hearing protection that is most effective.

Always follow the manufacturer’s instructions for cleaning and storage of reusable hearing protection.


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2.2 Safety Signs

2.2.1 Area Safety Signs

Safety signs should be installed to alert any personnel entering dangerous areas. Several safety signs may be required and located so they can be seen from any direction the equipment might be approached.

Suggested text for these signs in appropriate language would be:

WARNING

EXPOSED MOVING PARTS - KEEP AWAY

WARNING

LOCK OUT POWER BEFORE

PERFORMING MAINTENANCE

WARNING

HEARING PROTECTION REQUIRED


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If personnel working with this equipment cannot readily read or understand English, warning signs on the equipment and procedures set forth in this manual must be translated and provided for their benefit in a language they understand. Multilingual signs may be needed.

Location of signs will depend upon the specific design and placement of the equipment. For example; the signs may be located above catwalks, or affixed to walls adjacent to the equipment, or on the equipment itself. Verify that these signs are visible to the operator during operation and visible to persons approaching the area of the machine.

2.2.2 Equipment Safety Signs

(By FLSmidth)

Safety and warning signs are shop mounted to the equipment. These signs must not be removed.

These signs must be kept clean and must not be covered up.

If the signs are damaged or deteriorated; replace them.

2.3 Environmental Management Cautions

CAUTION!

2.3.1 Paint

Field painting must be done in accordance with paint manufacturer's instructions. Use accepted industry methods to limit paint overspray or dripping of wet paint.

Clean up after field painting must be done in compliance with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Storage of unused paint must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Removal of old paint from component surfaces must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Disposal or recycling of old paint, in any form, must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.


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2.3.2 Cleaning Agents

Storage, use, and disposal of cleaning agents must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.3 Cleaning Materials

Storage, disposal, or recycling of cleaning materials must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.4 Grease

Storage of grease must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Most greases used for lubrication are considered "HAZARDOUS", and must be handled appropriately by operating and maintenance personnel. Proper safety procedures must be followed when applying, cleaning up or disposing of grease lubricants.

Disposal or recycling of grease must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.5 Lubricating Oil

Storage of lubricating oil must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Most oils used for lubrication are considered "HAZARDOUS", and must be handled appropriately by operating and maintenance personnel. Proper safety procedures must be followed when applying, cleaning up or disposing of lubricating oil.

Disposal or recycling of lubricating oil must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.6 Hydraulic Oil

Storage of hydraulic oil must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.


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Most hydraulic oils are considered "HAZARDOUS", and must be handled appropriately by operating and maintenance personnel. Proper safety procedures must be followed when applying, cleaning up or disposing of hydraulic oil.

Disposal or recycling of hydraulic oil must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.7 Process Samples

Storage of process samples must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

Depending on the process, the samples may be considered "HAZARDOUS", and must be handled appropriately. Proper safety procedures must be followed when taking and analyzing samples, and when disposing of sample materials following testing.

2.3.8 Used Parts and Materials

Disposal or recycling of used parts and materials must comply with manufacturer's instructions and local and national environmental protection regulations, and should be done in accordance with plant policies and procedures.

2.3.9 Installation and Maintenance Equipment

All tools and equipment used for installation and/or maintenance of this equipment must be used or operated in compliance with the manufacturer's instructions and in accordance with plant policies and procedures. Use and storage of tools and equipment must also comply with local and national environmental protection regulations.


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Chapter 3: Installation

3.1 Tank Support Structure The foundation must support the Total Weight of the tank, mechanism and slurry, as specified on the “Load Data” table on the Anchor Chair Layout and Foundations drawing. The supports should also be designed to achieve and maintain the level tolerances, below, when filled with slurry.

For concrete foundation, a tank should be level in two directions (90o) within ±1/8" (3 mm) in 10'-0, (3048 mm).

A level-mounting surface may save leveling time later when a tank is installed. If pre-leveling will be done, check the foundation for level with a transit, from side to side and in the direction of flow. Shim or grout for level referring to the Tank Installation instructions on a following page.

If a concrete foundation is used, cast-in anchor bolts (not by FLSmidth) must be sized and located for the bolt locations (mounting holes per tank) shown on the Anchor Chair Layout and Foundations drawing.

Connection box and discharge box supports must be located and oriented as shown on the Anchor Arrangement drawing. The top surfaces of the supports must be level at the elevations specified.

Note the lift out height of the mechanism for determining clearance for lifting equipment (not by FLSmidth). Refer to the General Arrangement drawings.

3.2 Tank and Component Lifting

WARNING: Use extreme care when lifting structural components, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must be wearing adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.

WARNING: STAND CLEAR AS THE EQUIPMENT IS LIFTED!


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CAUTION: All rigging and lifting must be done by experienced personnel who are fully trained in the proper procedures for rigging and lifting of large structural components.

CAUTION: Make sure the rigging and hoist equipment are of adequate capacity.

1. The mechanism assemblies are shipped separately from the tanks, and mounted on shipping

support structures. Refer to the Single Tank General Arrangement drawings.

2. Check the crane and rigging capacities to be sure they are capable of supporting the weight of the equipment (tank or mechanism) as given on the drawings.

3. Before each component or assembly is removed from the carrier, check to be sure the blocking, bracing and banding securing it to the carrier have been removed and it is ready for moving.

WARNING: Do not remove the internal blocking, bracing or any other supporting or protecting materials until the tank installation is completed.

4. Use multiple-point lifting whenever possible. All lifting lugs must be used. Refer to the

Mechanism Assembly Rigging Illustration on the Mechanism Assembly.

5. When lifting structural members of this equipment, avoid twisting or bending the members. Use spreader beams, as necessary, to fully support the pieces as they are lifted.

6. Make sure the equipment being lifted or the lifting equipment cannot come into contact with overhead electrical cables, etc.

7. Lift the equipment an inch or two off the carrier to be sure it is free to be moved and balanced correctly. Keep it level at all times during the lifting. It may be necessary to use additional snubber cable to stabilize the unit.

8. Do not bounce the equipment or move it in jerks and never allow it to strike the ground, foundation or other objects.

3.3 Tank Installation 1. Referring to the Tank and Component Lifting procedures on a previous page and using all of

the lifting lugs provided, set the first tank assembly in place on the support structure (not by FLSmidth), orienting as shown on the General Arrangement and Re-cleaner Assembly drawings.


Contents 25

2. Check the tank top rim angle for level. Check tank level in two directions (90°) side to side. The tank must be level within 3/8" (10 mm) overall.

Figure 3.3-1

1. Tank Rim Angle 2. Peripheral Launder (Ref.) 3. Maximum 3/8" (10mm) overall

3. Level a tank by shimming with stainless steel shims (not by FLSmidth) between the tank

bottom and the foundation at the anchor bolt locations. Shims must be used where there is a gap between the tank bottom and the foundation.

4. Install and secure the tank anchor bolts.

5. Grout (not by FLSmidth) between the tank bottom and the foundation, as required, using a free flowing gravity fed grout (not by FLSmidth). A temporary dam (not by FLSmidth) will be required around the base of the tank to retain the grout in place until it sets. The tank bottom must be fully supported by the grout without gaps or voids. Allow the grout to set completely, then, remove the temporary grout dam (not by FLSmidth).

NOTE: FLSmidth is not responsible for grouting the tank, the grouting material, or accuracy of placement. Grouting specifications and placement of the grout are solely the responsibility of the user, or his agent.

6. Prior to installing connection box, type 1 on the tank; install the dart valve within the connection box. Refer to the instructions given on the Connection Box, Type-1 Assembly drawings.

7. Follow the procedures listed above for the installation of connection box, type 2. Refer to the Connection Box, Typs-2 Assembly drawings.


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8. After the dart valves have been installed within the connection box, place the connection boxes in position on tank number 1; orienting as shown on the Connection and Discharge Box General Arrangement. Refer to the Tank and Component Lifting procedures.

9. Secure the rubber expansion joint to tank number 1 using the gasket and fasteners specified. Then connect the connection box upper housing weldment to the expansion joint using the gasket and fasteners specified.

10. Referring to the Tank and Component Lifting procedures on a previous page and using all of the lifting lugs provided, set the second tank assembly in place on the support structure (not by FLSmidth), orienting as shown on the General Arrangement and Re-cleaner Assembly drawings.

11. Check the tank top rim angle for level. Check tank level in two directions (90o) side to side. Refer to Figure 1. The tank must be level within 3/8" (10 mm) overall.

12. Level the tank by shimming with stainless steel shims (not by FLSmidth) between the tank bottom and the foundation at the anchor bolt locations. Shims must be used where there is a gap between the tank bottom and the foundation.

13. Attach tank number 2 to the proceeding connection boxes, using the connecting pipes and fasteners specified.




16. Referring to the Tank and Component Lifting procedures on a previous page and using all of the lifting lugs provided, set the third tank assembly in place on the support structure (not by FLSmidth), orienting as shown on the General Arrangement and Re-cleaner Assembly drawings.

17. Check the tank top rim angle for level. Check tank level in two directions (90o) side to side. Refer to Figure 1. The tank must be level within 3/8" (10 mm) overall.

18. Level the tank by shimming with stainless steel shims (not by FLSmidth) between the tank bottom and the foundation at the anchor bolt locations. Shims must be used where there is a gap between the tank bottom and the foundation.

19. Place the velocity ramp in position in tank number 2, as shown on the Re-Cleaner Assembly drawing.


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20. Attach the tank number 3 to tank number 2 and the velocity ramp, using the gasket and fasteners specified at the flange connection.




23. Referring to the Tank and Component Lifting procedures on a previous page, place the discharge box in position on tank number 3.

24. Secure the discharge box to tank number 3 using the circular expansion joint and fasteners specified.

25. Referring to the Tank and Component Lifting procedures on a previous page and using all of the lifting lugs provided, set the first feed box in place on the support structure (not by FLSmidth), orienting as shown on the General Arrangement and Re-cleaner Assembly drawings.

26. Place the velocity ramp in position in feed box number 1.

27. Mount the feed box number 1 and velocity ramp to tank number 1, using the fasteners specified.

28. Install and secure the feed box anchor bolts.

29. Referring to the Tank and Component Lifting procedures on a previous page and using all of the lifting lugs provided, set the second feed box in place on the support structure (not by FLSmidth), orienting as shown on the General Arrangement and Re-cleaner Assembly drawings.

30. Place the velocity ramp in position in feed box number 2.

31. Mount the feed box number 2 and velocity ramp to tank number 2, using the fasteners specified.

32. Install and secure the feed box anchor bolts.

3.4 Install the Velocity Cone, Draft Tube, False Floor Plates and Manway Door

Refer to the Cell Type I Assembly, Cell Type II Assembly and Cell Type III Assembly drawings.


Contents 28

1. Place each velocity cone in position in the tank weldment, as shown on the Cell Assembly drawing; mounting the velocity cone to the supports in the tank weldment bottom using the fasteners specified.

2. Place the draft tube and false floor in position in the tank, as shown on the Cell Assembly drawing; mounting the draft tube and false floor to the supports in the tank bottom, using the fasteners specified.

NOTE: Do not install the split draft tube collar at this time. The split collar will be installed following installation of the mechanism assembly.

3. Install the grommets in the false floor, if not factory installed.

4. Referring to the Cell Assembly drawing, mount the manway door swing arm on the tank, using the cotter pin specified.

5. Mount the manway lifting hook to the manway door swing arm, using the nuts and washers specified.

6. Hang the manway door from the manway lifting hook, orienting as shown on the Cell Assembly drawing.

7. Place the manway door gasket in position on the manway door flange, using adhesive sealant to hold it in position, and aligning the bolt holes in the gasket with the flange bolt holes.

8. Swing the manway door into position and bolt it to the manway door flange, using the fasteners specified.

9. Tighten the manway door fasteners in a cross diameter sequence to the point that an effective seal is obtained.


Contents 29

3.5 Install the Baffles, Radial Launders, and Weirs 1. Referring to the Cell Assembly drawings, mount the baffle plates to the brackets on the

peripheral launder, using the fasteners specified.

2. Referring to the Radial Launder, Weir and Baffle Plate Assembly drawing and Figure 1, adhere the adhesive foam strip to the inside surface of the peripheral launder following the perimeter of the radial launder cutout.

Figure 3.5-1

1. Radial launder opening 2. Peripheral launder 3. Radial Launder

4. Adhesive foam strip 5. Radial launder-to-backing plate fasteners 6. Weir bar

3. Referring to the Radial Launder, Weir and Baffle Plate Assembly drawing, mount the radial

launders to the brackets on the peripheral launder, using the fasteners specified.

4. Referring to the Radial Launder, Weir and Baffle Plate Assembly drawing and Radial Launder Assembly drawings, install the radial launder backing plates, using the fasteners specified. Do not secure the fasteners at this time.

5. Referring to the Radial Launder, Weir and Baffle Plate Assembly drawing and Figure 2, install the circumferential weir bars, adjusting them for level all around the periphery and secure the radial launder backing plate fasteners to clamp the ends of the weir bars in place.


Contents 30

Figure 3.5-2

1. Radial launder opening 2. Peripheral launder 3. Radial launder

4. Circumferential weir bar 5. Radial launder-to-backing place fasteners 6. Backing plate

6. Referring to Figure 3, install the weir clips over the weir bars and launder lip at the intervals

specified on the Radial Launder, Weir and Baffle Plate Assembly drawing to hold the weir bars in contact with the launder lip all around the periphery.


Contents 31

Figure 3.5-3

1. Circumferential weir bar 2. Peripheral launder lip 3. Weir clip

3.6 Install the Mechanism Assembly Due to shipping requirements, the mechanism assembly may ship partially or even fully disassembled. The following procedures should be used, as required, to assemble the mechanism assembly.

1. Prepare an assembly frame (not by FLSmidth) or substantial blocking that will support the equipment during assembly of the mechanism assembly. The support structure must be of adequate capacity to support the fully assembled mechanism assembly and must allow adequate clearance for installation of all components.

2. Place the mechanism frame on the support structure.


Contents 32

Figure 3.6-1

1. Support structure (not by FLSmidth) 2. Mechanism frame 3. Bearing stand

4. Bearing housing and shaft assembly 5. Standpipe and crowder 6. Disperser

7. Hood sectors 8. Star rotor 9. Air control assembly

10. Air seal 11. Motor mounting plate 12. Motor

13. Driven sheave 14. Drive sheave 15. Belt guard assembly

3. Referring to the Mechanism Assembly drawings, mount the bearing stand to the mechanism

frame, using the fasteners specified. Torque tighten the fasteners to the value specified on the Mechanism Assembly drawings.

4. Referring to the Mechanism Assembly drawings, mount the bearing housing & shaft assembly to the bearing stand.

5. Referring to the Mechanism Assembly drawings, mount the motor support brackets to the bearing stand.


Contents 33

6. Referring to the Mechanism Assembly drawings, mount the standpipe and crowder to the mechanism frame.

7. Referring to the Mechanism Assembly drawings, mount the star rotor to the bearing housing and shaft. Torque tighten the fasteners to the value specified on the Mechanism Assembly drawings.

8. Referring to the Mechanism Assembly drawings, mount the disperser to the standpipe and crowder.

9. Referring to the Mechanism Assembly drawings, mount the hood sectors to the disperser, using the fasteners specified. As each sector is installed, it must be interlocked with the previously installed sector. The sectors are then attached to each other at the splice using the hood sector bosses, hood clamps, capscrews and washers specified. Mount the bolt caps over the capscrew heads, as shown on the Assembly drawing.

10. Apply adhesive sealant to the air control assembly mounting surface on the mechanism frame and mount the right and left cover plates to the mechanism frame, using the fasteners specified.

NOTE: Apply adhesive sealant to the lips of the right and left cover plate before attaching the air control weldment to the cover plates.

11. Mount the air control weldment to the mechanism frame and cover plates using the specified fasteners.

12. Referring to the Mechanism Assembly drawing, mount the air seal around the rotor shaft and install the hose clamps.

13. Referring to the Air Control Assembly drawing, mount the butterfly valve and air control stub to the air control weldment, using the fasteners specified.

14. Attach the motor to the motor mounting plate, using the fasteners specified.

15. Set the motor with motor mounting plate in position on the motor support brackets and install the adjusting rods and motor mounting plate-to-motor support bracket fasteners. Refer to the Mechanism Assembly drawing. Do not secure the motor mounting plate-to-motor support bracket fasteners at this time.


Contents 34

Figure 3.6-2

1. Bearing stand 2. Motor mounting plate 3. Motor

4. Motor support bracket 5. Adjusting rod 6. Motor mounting plate-to-motor support bracket fasteners

7. Motor-to-motor mounting plate fasteners

8. Mechanism frame

16. Referring to the Mechanism Assembly drawings, mount the outrigger beams to the mechanism

frame, using the fasteners specified. Torque tighten the fasteners to the value specified on the Mechanism Assembly drawings.

17. Do not install the belt guard assembly, sheaves or V-belts at this time.


Contents 35

3.6.1 Install the Mechanism Assembly in the Tank

WARNING: Use extreme care when lifting structural components, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must be wearing adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.




1. Attach lifting cables (not by FLSmidth) to the lifting eyes on the mechanism frame. Refer to

the Mechanism Assembly drawing. Use a spreader beam assembly (not by FLSmidth) to provide a vertical lift from each lifting eye.

2. Referring to the lifting Warnings and Cautions above and to the Tank and Component Lifting instructions, lift the mechanism assembly off the assembly stand or shoring and carefully place it in position on the tank, orienting as specified on the Re-cleaner Assembly drawing.

3. Referring to the Re-cleaner Assembly drawing, attach the mechanism frame and outrigger beams to the mounting pads on the tank, using the fasteners specified. Do not torque tighten the fasteners at this time.

3.6.2 Align Bearing Housing and Shaft Assembly 1. Check the bearing housing and shaft assembly for plumb using a machinist’s level. For the

shaft to be plumb (90° to horizontal ± 1°), the machinist’s level must read level in all directions within the specified level tolerance.

2. To plumb the shaft, realign the bearing housing and shaft assembly by loosening the bearing housing to bearing stand mounting bolts and, using the jacking bolts, shifting the bearing housing within the limits of the oversize mounting bolt holes.


Contents 36

Figure 3.6-3

1. Shim between housing and bearing stand

2. Mechanism frame 3. Bearing stand

4. Bearing housing and shaft assembly

5. Motor 6. Machinist’s level

7. Square

3. Re-secure the bearing housing and shaft assembly mounting bolts. If shaft plumb is still not

achieved, shim between the bearing housing and the bearing stand (see Mechanism Assembly drawing) using stainless steel shim stock. Retighten the bearing housing-to-bearing stand mounting bolts. Recheck rotor shaft plumb. If shaft plumb is still not achieved, contact your FLSmidth representative for additional recommendations.

3.6.3 Check Rotor for Concentricity with Draft Tube 1. Check for concentricity of the star rotor with the draft tube. Do this by measuring the distance

between the end of each rotor blade and the draft tube. The rotor should not be turned as the measurements are taken. The star rotor should be concentric to the draft tube and tank within ± 1/8” (± 3 mm). If the above tolerance cannot be achieved, this is an indication that the mechanism assembly is out of position and should be adjusted accordingly to bring the rotor and draft tube into alignment.


Contents 37

2. Loosen the mechanism frame-to-tank and mechanism outrigger beam-to-tank fasteners and adjust the position of the mechanism assembly, as necessary to center the star rotor over the draft tube.

3. Secure the mechanism frame-to-tank and mechanism outrigger beam-to-tank fasteners, referring to the Torque Values drawing.

3.6.4 Install the Split Collar 1. Assemble the split collar around the rotor, using the fasteners specified.

2. Mount the split collar to the draft tube, using the fasteners specified.

Figure 3.6-4

1. Draft tube 2. Split collar 3. Disperser

4. Star rotor 5. Hood sectors 6. Stand pipe and crowder


Contents 38

3.6.5 Check the Motor Shaft for Plumb 1. Check the motor shaft for plumb using a machinist’s level. The shaft must be plumb in all

directions.

2. Loosen the motor-to-motor mounting plate fasteners and adjust the motor for plumb. Secure the motor-to-motor mounting plate fasteners.

Figure 3.6-5

1. Motor shaft 2. Square 3. Motor mounting plate

4. Motor-to-motor mounting plate fasteners

5. Machinist’s level 6. Motor

3.6.6 Belt Guard, Sheave and V-Belt Installation 1. Referring to the Mechanism Assembly and Belt Guard Assembly drawings, mount the belt

guard base sectors to the bearing stand and each other, using the fasteners specified.

2. Mount the drive sheave on the motor shaft.

3. Mount the driven sheave on the bearing housing and shaft assembly shaft.

4. Check the sheaves for parallel alignment and adjust, as necessary. Secure all sheave fasteners.

5. Place the V-belts in position on the bearing housing and shaft assembly sheave.


Contents 39

Figure 3.6-6

Bearing stand Motor mounting plate Motor

Motor support bracket Adjusting rod Motor mounting plate-to-motor support bracket fasteners

Motor-to-motor mounting plate fasteners

Mechanism frame

6. Referring to the Mechanism Assembly drawing and to Figure 4, loosen the motor mounting

plate-to-motor support bracket fasteners and, using the adjusting rods, adjust the position of the motor to allow just enough slack for the V-belts to slip over the motor sheave and remain in place. There may be conditions where the sheaves provided will have more grooves than the number of belts provided. If this is the case, install the belts in the lowest parallel grooves. Any empty grooves should be at the top of the sheaves.

7. Tension the V-belts by turning the adjusting rods equally, together, to take up the slack in the belts. Proper alignment distributes the load equally to each V-belt.

For proper belt tensioning, refer to the belt tension plate on the belt guard, and as shown in Figure 5, for the required tension and deflection per belt. A V belt drive will successfully transmit its rated horsepower if the belts are properly tensioned. Do not exceed the specified belt tension.


Contents 40

NOTE: Excessive belt tension will cause excessive belt wear, reducing bearing life and may result in possible motor failure.

Figure 3.6-7

CAUTION: DO NOT OVERTIGHTEN V-BELTS

Lbs./Kg. Max. Per Belt / Band Deflection

8. After tensioning the V belts, tighten down and torque the motor mounting plate-to-motor

support bracket fasteners.

NOTE: Later, after a few days operation, the belts will seat themselves in the sheave grooves, and it may become necessary to readjust them. If the belts squeal, other than during start-up, repeat the procedure for proper belt tensioning.

9. Referring to the Mechanism Assembly and Belt Guard Assembly drawings, mount the top belt guard assembly in position on the belt guard base assembly.

In order to properly install the dart valve assembly in the discharge box, refer to the instructions given on the Discharge Box Assembly drawings.

3.7 Install Level Sensor Assembly 1. Insert the support post into the top of the level sensor mounting bracket, adjust for the

dimension specified on the Level Sensor Assembly drawing, and install the fasteners specified. Note that this dimension may need to be reset during operation to meet actual operating conditions.

2. Referring to the ultrasonic transmitter manufacturer’s instructions, mount the ultrasonic transmitter to the support post.


Contents 41

Figure 3.7-1

1. Level sensor mounting bracket 2. Adjustable support post 3. Fasteners specified

4. Level control rod 5. Level sensor target plate 6. Fasteners specified

7. Level sensor mounting clamp 8. Outrigger beam 9. Dimension specified

10. Dimension specified 11. Dimension specified 12. Fasteners specified

13. Ultrasonic transmitter

3. Place the level sensor mounting bracket with adjustable support post and the ultrasonic

transmitter on the outrigger beam, as shown on the Level Sensor Assembly. Attach the mounting bracket to the outrigger beam using the level sensor mounting clamp and fasteners specified.

4. Mount the top end of the level sensor brace to the level sensor mounting bracket, as shown on the Level Sensor Assembly drawing, using the U-bolt, nuts and washers specified.

5. Attach the bottom end of the level sensor brace to the outrigger beam, as shown on the Level Sensor Assembly drawing, using the anchor bolt, nut and washer specified.

6. Insert the level control rod with float up through the level sensor mounting bracket.


Contents 42

7. Mount the level sensor target plate to the float and rod, using the fasteners specified.

8. Position the float at the maximum anticipated float level position and check the “minimum” distance between the target plate and the ultrasonic transmitter. Adjust the elevation of the ultrasonic transmitter, if necessary, by repositioning the adjustable support post.

9. Refer to Electrical Power and Controls Installation on a following page.

3.8 Install the Froth Sensor Assembly 1. Referring to the ultrasonic level transmitter manufacturer’s instructions, mount the ultrasonic

transmitter to the froth sensor mounting bracket.

Figure 3.8-1

1. Froth sensor mounting bracket

2. Ultrasonic level transmitter 3. Level sensor clamp plate

4. Capscrew 5. Washer 6.

2. Place the froth sensor mounting bracket and the ultrasonic transmitter on the level sensor

clamp plate.


Contents 43

3. Attach the level sensor clamp plate to the mechanism support frames on tanks 1 and 3 using the washers and capscrews specified.

4. Refer to Electrical Power and Controls Installation on a following page.

3.9 Install the Electrical Power and Controls

3.9.1 Electrical controls FLSmidth does not furnish, locate or install the interconnecting wiring, pneumatic piping, etc. However, note that all interconnecting wiring and wiring connections must be in compliance with local and national electrical codes.

Be aware:

1. All wiring must be installed in heavy-current conduit that is securely anchored. Heavy flexible conduit must be used for all motor wiring. Bare conductors and wires are prohibited.

2. Whenever aluminum to copper or other dissimilar wiring materials connect, special splicer/spacers must be used to prevent contact of the materials. Also, an anti-oxidant is recommended at the connections. Anti-oxidant application prevents galvanic corrosion that can lead to electrical fire and dangerous breaks in the connections.

3. All electrical boxes and panels must be closed during operation or when the power is on to the equipment. Observe all warnings on the electrical panels and boxes.

4. Connect the mechanism drive motors to power according to the motor Manufacturer's Instructions and be sure motors are grounded. Rotor direction is a customer choice. FLSmidth recommends that the direction of rotation alternates from tank to tank (i.e.: every other rotor has the opposite, or reverse, direction of rotation of the rotor in the previous tank).

WARNING: Do not operate equipment with open electrical boxes or fittings.

WARNING: All guards and protective devices must be installed before the machine is started. Contact with belts, sheaves, or couplings can result in injury.

5. To ensure safe maintenance and repairs, the motors electrical service should have separate

lockouts and keys. And to prevent accidental restarting in the event of a power outage or overload, the wiring must have a reset or device that will not allow automatic starting of the motors when power is restored.

6. Install the pneumatic piping to the dart valve actuator and positioner, referring to the manufacturer’s instructions in the Accessory Equipment section of this manual. FLSmidth does


Contents 44

not furnish, locate or install the interconnecting pneumatic piping. All piping must be independently supported.

7. Install electrical wiring to the dart valve actuator and positioner, referring to the manufacturer’s instructions in the Accessory Equipment section of this manual.

8. Install electrical wiring to the level sensor assembly ultrasonic transmitter, referring to the manufacturer’s instructions in the Accessory Equipment section of this manual.

9. Install electrical wiring to the froth sensor assembly ultrasonic transmitter, referring to the manufacturer’s instructions in the Accessory Equipment section of this manual.

10. Refer to the Operation instructions in this manual.

3.10 Cable Trays, Grating, Walkway Assemblies and Stairway Assemblies Installation

1. Referring to the part numbers on the Walkway, Stairway and Platform Assembly drawings, install the walkways and stairways.

2. Install walkway and stairway grating, as required, using the grating clip assemblies specified. Refer to the Platform and Stairway Assembly drawings.

3. Referring to the part numbers on the Platform Assembly drawings, install the handrails.

4. Referring to the Cable Tray and Platform Assembly drawing, mount the cable tray to the outrigger beams, using the beam clamps and fasteners specified.

5. Referring to the Cable Tray and Platform Assembly drawing, connect the cable tray sections.

6. Referring to the Stairway and Interconnecting Stairway Assembly drawings, install the interconnecting stairway.

7. Referring to the Platform Arrangement drawing, locate and install the electrical mounting stands.

3.11 Final Inspection before Start-Up 1. Inspect the mechanism, tanks, feed box and connection/discharge boxes for any loose nuts

and bolts, for tools, debris and any other loose items. Make sure all guards, protective devices and covers are in place.

2. Water-test the tank and check the tank-to-box and tank-to-tank connections for leakage; minor leakage may occur at the bolted connections, but it will stop when sealed off by fine solids in the feed slurry. Adjust or make corrections, as required.

3. Check the controls for operation.


Contents 45

WARNING: Study these instructions carefully before putting the machines into service to ensure safe, satisfactory start-up and operation. All operating personnel must read and understand these instructions.

WARNING: If the machines will be out of service for a period of time, the electrical service must be locked out with an approved lockout and key to prevent accidental start-up and electrical dangers.

3.12 Mechanical Check

3.12.1 Final Mechanical Check At the completion of erection or installation of the equipment, an FLSmidth Service Representative must complete a final field mechanical check of the equipment. Unless accepted and signed-off by the Service Representative at the completion, the warranty will not be in effect.

Previous inspections will not count towards final acceptance unless a sign-off is obtained, in writing, from the Service Representative. Also, depending on any previous inspections, this final check may be an additional paid service call.

3.12.2 Arrangements for Service The "Final Mechanical Check List", included at the back of this manual, must be completed for each mechanism furnished before contacting your FLSmidth representative to arrange for the final field mechanical check.

Arrangements for final field mechanical check should be made at least two weeks in advance with your FLSmidth representative. Refer to the Offices page to contact him.

NOTE: Do Not Fill the Tank with Water

The mechanical check cannot be done if the tank is filled with water. If the mechanical check cannot be performed, an additional paid service day will be charged.


Contents 46

Chapter 4: Lubrication

4.1 Flotation Cell Drive The flotation drive is a combination of the Bearing Housing and Shaft Assembly manufactured by FLSmidth and a motor, V-belts and sheaves purchased from others. These instructions apply only to the FLSmidth manufactured bearing housing and shaft assembly.

For lubrication of equipment supplied by others, refer to the manufacturer's instructions included in the Accessory Equipment section of this manual.

4.2 Bearing Housing and Shaft Assembly The bearing housing and shaft assembly, which mounts to the bearing stand, consists of a cast iron bearing housing, upper and lower roller bearings, the rotor shaft, and upper and lower radial shaft seals, as shown on the Bearing Housing and Shaft Assembly drawing.

1. The seals prevent the loss of grease and the entry of dirt, moisture and other contaminants into the bearings.

2. The upper and lower inner shaft seals are lubricated through grease fittings by a grease gun.

3. Each bearing has a large grease cavity, lubricated through grease fittings by a grease gun. Pipe plugs on the bearing housing and end caps allow the discharge of old grease from the bearings. Both bearings are packed with grease at the factory.

4. Excessive lubrication of both bearings should be avoided. To prevent over-lubrication of the bearings, remove the pipe plugs during lubrication, as specified below, and reinstall them prior to operation. See WARNING below.

4.3 Lubrication Procedures and Schedule

WARNING: Whenever lubricating this equipment, shut down and lock out the electrical service to the drive. Do not remove or install the pipe plugs while the drive is running.

1. Schedule and lubricant - Lubrication should be performed according to the schedule below;

avoid over-lubrication. Also, use the recommended lubricant or equivalent high quality grease.

2. Grease the inner seal cavities.

a. At the grease fittings (1), apply grease, using a grease gun.

b. The cavity holds approximately 222cm3 of grease.


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3. Grease the upper bearing.

a. Remove the pipe plugs (2) and, using a grease gun, fill the housing with grease using the grease fitting (3) until grease begins to flow through the plug openings.

Figure 4.3-1

Inner seal cavity grease fitting Upper bearing grease flushing pipe plug

Upper bearing grease fitting

Upper bearing grease flushing pipe plug

Lower bearing grease flushing pipe plug

Lower bearing grease fitting

Lower bearing grease flushing pipe plug

Bearing housing Rotor shaft

NOTE: Removing the pipe plugs will also relieve pressure on the seals and prevent excessive grease collecting around the bearings, causing undesirable temperature rise.

b. Replace the pipe plugs (2).


Contents 48

c. Remove the pipe plugs (4) and, using a grease gun, fill the housing with grease using the grease fitting (3) until grease begins to flow through the plug openings.

d. Replace the pipe plugs (4).

CAUTION: Make sure the pipe plugs are reinstalled on completion of lubrication.

4. Grease the lower bearing.

a. Remove the pipe plugs (5) and, using a grease gun, fill the housing with grease using the grease fitting (6) until grease begins to flow through the plug openings.

NOTE: Removing the pipe plugs will also relieve pressure on the seals and prevent excessive grease collecting around the bearings, causing undesirable temperature rise.

b. Replace the pipe plugs (5).

c. Remove the pipe plugs (7) and, using a grease gun, fill the housing with grease using the grease fitting (6) until grease begins to flow through the plug openings.

d. Replace the pipe plugs (7).

CAUTION: Make sure the pipe plugs are reinstalled on completion of lubrication.

5. Disassembly lubrication - During a regularly scheduled overhaul of equipment and disassembly

for inspection or replacement of the bearings, thoroughly clean the housing of all grease. (Wash reused bearings with solvent and dry them before reassembly.) Work grease into the bearings between the rollers and cage, and pack each bearing cavity half full with the recommended grease. Refer to the Lubrication Schedule below.

6. Using a grease gun, lubricate the dart valve shaft stuffing boxes at installation with grease (see Lubrication Schedule below). Relubricate the dart valve shaft stuffing boxes every six months with approximately 1 cubic centimeter (0.03 oz.) of the recommended grease.

NOTE: Do not over-lubricate!


Contents 49

4.4 Lubrication Schedule

Component Lube Method Recommended Lubricant Service Interval

Upper Bearing Grease Gun - purge old grease

Mobil XHP 222 grease, or equivalent Every 3 months

Lower Bearing Grease Gun - purge old grease

Mobil XHP 222 grease, or equivalent

Every 3 months

Inner Seal Cavities Grease Gun Mobil XHP 222 grease, or equivalent

(the cavity holds approximately 222 cubic centimeters of grease)

Every 3 months

Main Drive Motor Refer to the manufacturer's instructions in the Accessory Equipment section of this manual.

Dart Valve Shaft Stuffing Boxes

Grease Gun Mobil XHP 222 grease, or equivalent Every 6 months


Contents 50

Chapter 5: Maintenance

5.1 Maintenance and Operation Warning SAFETY STATEMENT

No personnel, authorized or unauthorized, should depend wholly on safety devices to prevent accidents. Safety features and devices are meant only to supplement proper, careful, and safe practices on the part of the individual.

WARNING: If the safety procedures given in this manual are compromised or ignored, severe personal injury or death may occur. Safety practices accepted by the industry, as well as those dictated by the responsible regulatory agencies must be followed.

WARNING: Use extreme care when working around rotating or other moving parts, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must wear adequate safety equipment such as safety glasses, safety shoes, hard hat, hearing protection, etc. Loose fitting clothing, uncovered long hair, or jewelry must not be worn when working around rotating or moving equipment.

WARNING: Keep foreign objects, hands, etc. away from moving parts (chains, sprockets, belts, sheaves, etc.). Do not operate this equipment if guards have been removed, or are damaged. All guards and safety devices must be properly installed and functional before operating this equipment.

WARNING: Lock-out power from electrical equipment using a manual breaker or disconnect switch before starting any work or maintenance on the equipment. Lock and tag disconnect switch so it cannot be closed.

WARNING: Experience with and understanding of this equipment is essential for the safe operation and maintenance of the equipment. Therefore, in case of a question on how to safely proceed, contact FLSmidth immediately.


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WARNING: The fumes given off during welding and cutting can be injurious to the operator's health. Some fumes, such as those produced when working with Zinc; Cadmium and painted surfaces can be toxic.

WARNING: Use hearing protection anytime there is exposure to noise.

5.2 Before Operation, Maintenance or Repair of this Equipment

Read and understand the instructions in this manual.

As with any other mechanical equipment, there are safety concerns associated with the operation and maintenance of FLSmidth supplied equipment. It is absolutely essential that operators, maintenance personnel, and supervisors be instructed in safe working practices

Only personnel who have been trained in safety procedures for this equipment should be allowed around or in the area of the FLSmidth equipment or its auxiliaries. Training can be done by your own safety personnel or it can be conducted by an FLSmidth representative at your request.

Contact: FLSmidth, Midvale, Utah. Refer to the Offices page listed on the Table of Contents.

5.3 General Maintenance

WARNING: Refer to the Safety Procedures page in this manual before starting any inspections, maintenance or repairs. Lock out means the equipment electrical service must be locked out with a lockout and key.

General cleaning, inspection and preventive maintenance should be performed on a regular basis according to the recommended schedules and whenever the machines are shut down.

5.4 General Cleaning Keep platforms, stairs and the general work area free of obstacles, such as tools, rags, boxes, etc. Clean up lube spills, water, the general area, etc. Periodically remove solids accumulations by flushing down the mechanism below the motor drive, including the tank, and fully inspect the equipment. Leave drains open until the cleaning is complete.


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5.5 Drive V Belt Tension

WARNING: Lockout the power to the drive prior to starting work on the V Belt.

1. Check the belts every 6 months for tension, and tension the belts if they are squealing.

a. Remove the belt guard top.

b. Check the belts for cracking, wear or glazed inner surface, which are conditions requiring belt replacement.

o If one belt is damaged, all belts should be replaced.

NOTE: New V Belts must be installed as a matched set.

c. Place the V-belts over the sheaves and in the grooves without forcing them over the sides of the grooves.

NOTE: There may be conditions where the sheaves provided will have more grooves than the number of belts provided (see the Mechanism Assembly drawing for the required number of belts). If this is the case, install the belts in the lowest parallel grooves. Any empty grooves should be at the top of the sheaves.

d. Check the belts for tension, referring to the V-Belt Caution plate on the Beltguard Assembly for the required tension and deflection per belt.

e. Loosen the motor mounting plate-to-motor support bracket fasteners.

f. Tension the V-belts by turning the adjusting rods equally, together, to take up the slack in the belts.

NOTE: Proper alignment distributes the load equally to each V-belt.

g. Recheck tension, referring to the V-Belt Caution plate to ensure proper tension. A V belt drive will successfully transmit its rated capacity horsepower, if its belts are properly tensioned. Excessive tension will cause excessive belt wear, reduce motor bearing life and result in possible shaft assembly failure.


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Figure 5.5-1

1. CAUTION: Do Not overtighten V-belts

2. Lbf./ N per Belt / Band (Initial/ New Belts and Normal Operation range (min/max))

3. Deflection

h. Secure the motor mounting plate-to-motor support bracket fasteners.

i. Reinstall the belt guard top.

WARNING: Install the guard before the drive is operated.

5.6 Lubrication Check monthly for loss of grease around the bearing housing and shaft assembly seals at the upper and lower bearings.

Refer to the Lubrication Instructions for the recommended lubrication and schedule.

5.7 Air Control Assembly This air control assembly, mounted to the mechanism frame and over the standpipe, allows the flow of air between the standpipe and atmosphere. Air flow is controlled by means of a butterfly valve.


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Check regularly for accumulations of process froth and solids around the assembly and in the valve mounting spool on the air control weldment, and remove with a water spray for an unobstructed flow of air.

Check the butterfly valve regularly for smooth operation.

5.8 Star Rotor and Split Collar 1. During each shutdown, drain and flush down the tank so the rotor, split collar, hood,

disperser, standpipe and crowder can be inspected.

WARNING: Lockout the power prior to starting work.

2. Check the vanes of the rotor and the draft tube split collar for excessive wear or damage. Look

for metal showing through the rubber covering, for uneven wear, deep grooves, etc.

3. If a rotor assembly or split collar is removed or replaced, check the split collar for concentricity with the rotor. It must be centered around the rotor within ±1/8" (±3 mm) all around. For replacements or adjustments, refer to the instructions for "Maintenance and Repairs" that follow.

5.9 Hood Sectors During each shutdown, check the hood sectors for wear. Replace any sector with excessive wear. Check fasteners to insure they are properly tightened. Refer to the “Fastener Torque Specifications”.

5.10 Disperser Inspect the disperser and replace it if it is damaged, or has excessive wear. Check fasteners to insure they are properly tightened. Refer to the “Fastener Torque Specifications".

5.11 Standpipe and Crowder Assembly Check the lining for excessive wear, and for the separation of the liner from the standpipe. Replace the standpipe and crowder assembly if there is excessive wear, or if the liner is separated from the standpipe. Wash out any excess process solids build-up.

5.12 Tanks, Feed box and Connection/Discharge Boxes During each shutdown, flush the tanks, feed box and connection/discharge boxes. Inspect linings and repair, as required.


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5.13 Flotation Level Control Assembly 1. Process solids build-up in the level float area will cause false pulp height readings. This will

result in unstable pulp level control. The level float area should be checked weekly, or as experience dictates, for process solids build-up and cleaned with a high pressure water hose, if required.

2. Check the level control assembly regularly to ensure that the level control rod with target plate assembly moves up and down smoothly and without hang-up or binding. Clean or repair, as required.

5.14 Dart Valve and Actuators Process scale deposits can reduce the effectiveness of the valves. Check the valves monthly, (or periodically as experience dictates), for shaft movement during cylinder actuation, for leakage, etc. Check for adequate air pressure and clean air. Refer below for valve adjustments.

1. During each shutdown, flush the tanks and inspect the dart valve, rods, bearings, stuffing box assembly, expansion joint, etc. for wear.

2. Replace any parts that show excessive wear. Refer to "Stuffing Box Packing Replacement".

3. During plant shut downs, the valve darts and grommets (circular seats) should be checked for wear and cracking. The grommets are subject to high abrasion and will require periodic replacement.

a. Replace the grommet by raising the valve up to its maximum position.

b. Remove the bolt caps from the capscrews and remove the capscrews, nuts and washers mounting the grommet to the grommet plate.

c. Clean the grommet mounting surface, apply urethane sealant to the mounting surface on the grommet plate and install the new grommet.

d. Lower the valve to center the grommet and then install the capscrews, nuts and washers to secure the grommet in position.

e. Install the bolt caps over the tops of the mounting capscrews, using the sealant specified.

4. If a dart valve does not seat closed when the actuator is stroked to the full up position, a mechanical adjustment can be made. Do not make a valve adjustment with the level control.

a. Extend the valve rods so the dart valves bottom out in the grommets.

b. Watch as the dart valves descend to see if they enter and seat concentrically in the grommets.

c. The valve shafts should be perpendicular to and centered over the grommets.


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o If a dart valve is off center, adjust it referring to the Dart Valve Installation instructions.

d. The dart valves must also seat in the grommets when fully extended.

o If not, adjust the valve actuator, referring to the Actuator Manufacturer’s Instructions, until the dart valve seats in the grommet opening.

o If the dart valve is worn and will not seat in the grommet opening, the dart valve should be replaced.

e. Make sure the fasteners are secure.

5. Check valve rod guide bearing assemblies for wear or loose fasteners. Adjust, or replace, as necessary.

• If a dart valve pneumatic actuator fails to actuate, check for a broken air line or connection or a blocked air line.

NOTE: Air pressures in excess of the maximum specified by the manufacturer can damage the actuator.

6. Lubricate the dart valve stuffing boxes; refer to the Lubrication Instructions for the recommended lubricant and schedule.

5.15 Fasteners Check all fasteners on a regular basis, at least once every 6 months, to be sure they are secure. Refer to the “Fastener Torque Specifications” on a following page. Any fasteners that are missing must be replaced immediately.

The mechanism assembly must be partially disassembled, removed from the tank, and placed on a maintenance stand (not by FLSmidth) or on temporary shoring (not by FLSmidth) that will allow adequate clearance for disassembly and reassembly of the mechanism assembly components.

5.16 Removal of Complete Mechanism Prepare a maintenance stand (not by FLSmidth) or temporary shoring (not by FLSmidth) that is of adequate capacity to support the total weight of the mechanism assembly, as given on the Mechanism Assembly drawing.

WARNING: Use extreme care when lifting structural components, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must wear adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.


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1. Lock out and disconnect electrical power to the drive motor, level sensor assembly and forth

sensor assemblies. Disconnect air piping to the actuator assemblies.

2. Remove platforms and stairways, as necessary.

3. Remove the level sensor assembly from the outrigger beam.

4. Remove the froth sensor assembly from the mechanism support frames (tanks 1 and 3).

5. Attach lifting cables (not by FLSmidth) to the lifting eyes on the mechanism assembly mechanism frame. Refer to the Mechanism Assembly drawing.

6. Use a spreader beam assembly (not by FLSmidth) to provide a vertical lift from each lifting eye.

7. Support the mechanism assembly with the lifting equipment and unbolt the mechanism frame and outrigger beams from the tank. Refer to the Final Assembly and Mechanism Assembly drawings.

8. Lift the mechanism assembly from the tank, taking care to avoid damaging the dart valve assemblies, hood sectors, rotor, disperser and radial launder assemblies, and place it in a maintenance area on a maintenance stand (not by FLSmidth) or temporary shoring (not by FLSmidth) that is of adequate capacity to support the total weight of the mechanism assembly, for further disassembly and maintenance.

9. Refer to Component Removal and Installation on a following page.

5.17 Reinstallation of Complete Mechanism 1. Attach lifting cables (not by FLSmidth) to the lifting eyes on the mechanism frame. Refer to

the Mechanism Assembly drawing.

2. Use a spreader beam assembly (not by FLSmidth) to provide a vertical lift from each lifting eye.


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3. Referring to the lifting Warnings and Cautions on a previous page and to the Tank and Component Lifting instructions, lift the mechanism assembly off the maintenance stand or shoring and carefully place it in position on the tank, orienting as specified on the Re-Cleaner Assembly drawing.

NOTE: Take care to avoid damaging the dart valve assemblies and radial launder assemblies as the mechanism assembly is lowered into position on the tank.

4. Attach the mechanism frame and outrigger beams to the mounting pads on the tank, using the fasteners specified. Do not torque tighten the fasteners at this time.

5. Check for concentricity of the star rotor with the draft tube.

a. Measure the distance between the end of each rotor blade and the draft tube.

b. The rotor should not be turned as the measurements are taken. The star rotor should be concentric to the draft tube and tank within ±1/8” (± 3 mm).

o If the above tolerance cannot be achieved, this is an indication that the mechanism assembly is out of position and should be adjusted accordingly to bring the rotor and draft tube into alignment.

6. Loosen the mechanism frame-to-tank and outrigger beam-to-tank fasteners and adjust the position of the mechanism assembly, as necessary to center the star rotor over the draft tube.

7. Secure the mechanism frame-to-tank and outrigger beam-to-tank fasteners, referring to the Torque Values drawing.

8. Reinstall the level sensor assembly and froth sensor assembly (tanks 1 and 3). Refer to the instructions in the Installation section of this manual.

9. Reinstall platforms and stairways, referring to the instructions in the Installation section of this manual.

10. Reconnect electrical power to the drive motor, level sensor assembly and froth sensor assembly, as required.

5.18 Component Removal and Installation

5.18.1 Removal by Parts NOTE: The mechanism assembly must be removed from the tank and placed on a maintenance stand (not by FLSmidth) or on temporary shoring (not by FLSmidth) that will allow adequate clearance for disassembly and reassembly of the mechanism assembly components.

Refer to the Mechanism Assembly drawing.


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WARNING: Use extreme care when lifting the components, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must wear adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.

CAUTION: All rigging and lifting must be done by experienced personnel who are fully trained in the proper procedures for rigging and lifting of the motor.


WARNING: Stand clear as the equipment is lifted!

WARNING: Lock out power to the motor using a manual breaker or disconnect switch before starting any work or maintenance on the equipment. Lock and tag disconnect switch so it cannot be closed.

1. Disconnect and remove the top belt guard using the lifting eyes on the guard.

2. Remove the V-belts by loosening the motor mounting plate-to-motor support bracket fasteners and turning the adjusting rods equally until the motor mounting plate moves enough to allow belt removal.

3. Referring to the Mechanism Assembly drawing, remove the drive sheave from the motor shaft and the driven sheave from the rotor shaft.

4. Remove the belt guard bases.


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Figure 5.18-1

1. Support structure (not by FLSmidth)

2. Mechanism frame 3. Bearing stand

4. Bearing housing & shaft assembly 5. Standpipe and crowder 6. Disperser

7. Hood sectors 8. Star rotor 9. Air control assembly

10. Air seal 11. Motor mounting plate 12. Motor

13. Driven sheave 14. Drive sheave 15. Belt guard assembly

5.18.2 Motor

WARNING: Lock out power to the motor using a manual breaker or disconnect switch before starting any work or maintenance on the equipment. Lock and tag disconnect switch so it cannot be closed.

REMOVAL: After the belt guard, V-belts, drive sheave and belt guard bases have been removed follow the steps below:


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1. Support the motor with lifting equipment so that the bolts attaching the motor to the motor mounting plate can be loosened safely. Refer to the Mechanism Assembly drawing.

2. Disconnect the capscrews and nuts with washers connecting the motor to the motor mounting plate.

3. Lift the motor, as required, and remove it from the mechanism assembly.

INSTALLATION:

1. Follow the reverse of the removal procedures.

2. Tension the belts referring to the General Maintenance instructions on a preceding page.

5.18.3 Air Inlet Assembly REMOVAL:

1. Unbolt and remove the butterfly valve and air control stub.

2. Unbolt and remove the air seal assembly.

3. Unbolt and remove the air control weldment and cover plates from the mounting frame and from around the bearing housing. Remove old gaskets and sealant.

INSTALLATION:

1. Referring to the Mechanism Assembly and Air Control Assembly drawings, mount the cover plates to the mechanism frame, using the fasteners specified.

2. Referring to the Mechanism Assembly and Air Control Assembly drawings, mount the air control weldment to the mechanism frame and cover plates, using the fasteners and sealant specified.

3. Referring to the Mechanism Assembly drawing and Figure 1, mount the air seal around the rotor shaft and install the hose clamps.

4. Referring to the Air Control Assembly drawing, mount the butterfly valve and air control stub to the air control weldment, using the fasteners specified.

5.18.4 Hood Sectors Refer to the Mechanism Assembly drawings. The hood consists of sections that bolt to the disperser and connect to each other. The disperser should be attached to the standpipe and crowder during hood removal and installation for ease of sector installation.

REMOVAL:

1. The mechanism assembly must remain upright on a maintenance stand or blocking for sector removal.

NOTE: The hood sections can be permanently damaged if the mechanism is laid on its side.


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2. Disconnect the hood sectors from each other by removing the bolt caps, capscrews, nuts, washers and hood sector bosses.

NOTE: Save the capscrews, nuts washers, hood sector bosses and bolt caps for reuse if there are no signs of wear.

3. Unbolt the hood sectors from the disperser.

NOTE: Save the capscrews and washers for reuse if there are no signs of wear.

INSTALLATION:

4. Referring to the Mechanism Assembly drawing, mount the hood sectors to the disperser using the hood sector bosses and fasteners specified.

NOTE: Tighten fasteners finger tight only to allow the hood sections to align. Do not final tighten any fasteners until all sectors are in place and aligned.

5. Referring to the Mechanism Assembly drawing, attach the hood sectors to each other using the hood sector bosses, capscrews, nuts and washers specified.

6. Mount the bolt caps over the nuts and capscrew heads, as shown on the Assembly drawing.

7. Tighten the hood sector-to-disperser capscrews to the value specified on the Torque Values drawing.

5.18.5 Disperser Refer to the Mechanism Assembly drawings.

REMOVAL:

1. The mechanism assembly must be supported on a maintenance stand or blocking for disperser removal.

2. Block the mechanism high enough to provide the necessary clearance from the bottom of the rotor to the ground for removal of the disperser.

NOTE: The clearance should include additional space for the device used to lift the disperser.

3. Remove the hood sectors from the disperser, referring to the above instructions.

4. Support the disperser in position with an adjustable device, such as lift truck, jacks and pallet, etc., until all capscrews connecting it to the standpipe and crowder have been removed.

5. Unbolt the disperser from the standpipe and crowder and lower it below the star rotor for removal.

INSTALLATION:


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1. Using the same device for removal, lift the disperser up to the standpipe and raise it into position so the bolt holes are aligned.

2. Apply an anti-seize compound to the threads of the capscrews, then install the capscrews with washers.

3. Tighten all bolts equally in half turns to draw the disperser up evenly, until all bolts are tightened to the value specified on the Torque Values drawing.

5.18.6 Standpipe and Crowder REMOVAL:

Support the standpipe and crowder with lifting equipment and unbolt and remove the standpipe and crowder from the mechanism frame.

INSTALLATION:

1. Using the lifting equipment, lift the standpipe and crowder into position and bolt it to the mechanism frame, using the fasteners specified.

2. Tighten the fasteners to the value specified on the Torque Values drawing

5.18.7 Star Rotor REMOVAL:

CAUTION: The star rotor is heavy. Lifting equipment of adequate capacity must be used to support the star rotor before it is disconnected from the rotor coupling.

1. Loosen the rotor shaft coupling-to-rotor hex head capscrews and nuts, but do not remove

them.

2. Support the star rotor from below with the lifting equipment so it will not fall when the capscrews and nuts are removed.

3. Remove the capscrews, nuts and washers, and lower the star rotor enough to clear the disperser.

4. Remove the star rotor, and set it on blocking large enough to support it with at least (4) vanes.

INSTALLATION:

1. Referring to the Mechanism Assembly drawing, mount the star rotor to the rotor shaft coupling, using the fasteners specified.

2. Torque tighten the fasteners to the value specified on the Mechanism Assembly drawing.


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5.18.8 Draft Tube Split Collar: REMOVAL:

The split collar, which mounts on top of the draft tube and false floor in the bottom of the cell, will wear over time despite its rubber covering.

1. Disconnect the split collar from the draft tube and false floor.

2. Save the bolts and nuts for reuse, if they are in good condition.

3. Unbolt the halves of the split collar from each other and remove the split collar from around the rotor.

INSTALLATION:

1. Referring to the Tank Assembly drawings, assemble the split collar halves around the star rotor, using the fasteners specified.

2. Attach the split collar assembly to the draft tube and false floor, using the fasteners specified.

3. Check the split collar for concentricity with the rotor. It must be centered around the rotor within ±1/8" (±3 mm) all around.

5.18.9 Belt Guard and Sheaves REMOVAL:

1. Un-latch and remove the belt guard top. Refer to the Belt Guard Assembly drawing.

2. Referring to the Inspection and General Maintenance instructions on a previous page, release V-belt tension and remove the V-belts.

3. Remove the drive and driven sheaves, referring to the sheave manufacturer’s instructions.

4. Unbolt and remove the belt guard base sections from the bearing stand.

INSTALLATION:

1. Referring to the Mechanism Assembly and Belt Guard Assembly drawings, install the belt guard bases, using the fasteners specified.

2. Mount the drive sheave on the motor shaft, referring to the Mechanism Assembly drawing and to the sheave manufacturer’s instructions.

NOTE: Use standard mounting for sheaves whenever possible.

3. Mount the driven sheave on the rotor shaft, referring to the Mechanism Assembly drawing and to the sheave manufacturer’s instructions. Use standard mounting for sheaves whenever possible.

4. Check the sheaves for parallel alignment and adjust, as necessary.


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5. Secure all sheave fasteners.

6. Install and tension the belts, referring to the belt installation procedures in the Installation section of this manual.

7. Referring to the Mechanism Assembly and Belt Guard Assembly drawings, mount the belt guard top in position on the mechanism assembly.

5.18.10 Bearing Housing and Shaft Assembly REMOVAL:

Refer to the Bearing Housing and Shaft Assembly and Mechanism Assembly drawings.

WARNING: Experience with or understanding of this equipment is essential for the safe disassembly and repair of the equipment. Therefore, in case of a question on how to safely proceed, contact FLSmidth immediately.

WARNING: Lock out power from electrical equipment using a manual breaker or disconnect switch before starting any work or maintenance on the equipment. Lock and tag disconnect switch so it cannot be closed.

WARNING: Use extreme care when lifting the bearing housing and shaft assembly, to prevent injuries to yourself or others. Also, anyone entering the area of this equipment must wear adequate safety equipment such as safety glasses, safety shoes, hard hat, etc.

CAUTION: All rigging and lifting must be done by experienced personnel who are fully trained in the proper procedures for rigging and lifting of the equipment.


WARNING: Stand clear as the equipment is lifted!

1. Remove the mechanism assembly from the tank, as covered in the Mechanism Removal for

Maintenance instructions on a previous page.


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2. Remove the belt guard, belts and driven sheave, referring to the instructions on a previous page.

3. Remove the air control assembly, referring to the instructions on a previous page.

4. Disconnect and remove the star rotor from the rotor shaft, referring to the instructions on a previous page.

5. Attach lifting equipment to the bearing housing and shaft assembly. Referring to the Mechanism Assembly drawing, unbolt and remove the bearing housing and shaft assembly from the bearing stand.

6. The bearing housing and shaft assembly must be sent to an approved FLSmidth facility/shop for any maintenance requiring disassembly and reassembly of the bearing housing and shaft assembly components. Contact your FLSmidth representative for recommendations.

INSTALLATION:

1. Referring to the lifting Cautions above, mount the bearing housing and shaft assembly to the bearing stand, as shown on the Mechanism Assembly drawing.

2. Mount the star rotor to the rotor shaft, referring to the instructions on a previous page.

3. Reinstall the mechanism assembly in the tank, referring to the Mechanism Removal for Maintenance instructions in the Maintenance section of this manual, and to the Mechanism Installation instructions in the Installation section of this manual.

4. Lubricate the bearings, referring to the Lubrication instructions section of this manual.

5. Referring to the Mechanism Installation instructions in the Installation section of this manual, reinstall belt guards, sheaves, drive belts, etc.

5.19 Dart Valve Maintenance

5.19.1 Dart Valve Replacement 1. Disconnect pneumatic piping to the actuator assembly.

2. Connect lifting cables to the lifting holes on the actuator support mounting channels, located on the upper housing weldment.

3. Remove the fasteners connecting the upper housing and dart valve seat to the lower housing.

4. Lift the upper housing with dart valve seat clear of the lower housing.


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Figure 5.19-1

1. Upper housing 2. Lower housing 3. Dart valve seat

4. Dart valve

5. Support the upper housing and dart valve seat in position with temporary blocking that will

allow adequate clearance for dart valve removal from the shaft.

6. Remove the hose and unscrew the hex nut with washer.

7. Remove the dart valve from the end of the shaft.

8. Place the new dart valve on the end of the shaft, using the specified sealant at the dart valve-to-valve shaft sleeve connection, as shown.


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Figure 5.19-2

1. Dart valve 2. Dart valve seat 3. Upper housing

4. Lower housing 5. Shaft 6. Valve shaft sleeve

7. Dart valve cover 8. Hex nut 9. Hose

10. Washer 11. Sealant specified 12. Flat head setscrew

13. Hex nut 14. Capscrew 15. Washer

9. Install and secure the hex nut with washer, using the specified sealant at the washer-to-dart

valve cover connection, as shown.

10. Install the hose over the hex nut.

11. Set the upper housing with dart valve seat in position on the lower housing, aligning the mounting holes in the housings and dart valve seat.

12. Install the upper housing and dart valve seat-to-lower housing fasteners hand tight.

13. Check the dart valve is fully seated in the dart valve seat. Adjust the dart valve seat, as necessary.

14. Secure the upper housing and dart valve seat-to-lower housing fasteners.

5.19.2 Dart Valve Seat Replacement 1. Referring to the dart valve replacement instructions above, remove the dart valve from the

shaft.

2. Lift the upper housing from the temporary blocking and remove the dart valve seat.


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3. Set the new dart valve seat in position.

4. Install the dart valve, referring to the dart valve replacement instruction above.

5. Set the upper housing with dart valve seat in position on the lower housing, aligning the mounting holes in the housings and dart valve seat.

6. Install the upper housing and dart valve seat-to-lower housing fasteners hand tight.

7. Check the dart valve is fully seated in the dart valve seat. Adjust the dart valve seat, as necessary.

8. Secure the upper housing and dart valve seat-to-lower housing fasteners

5.19.3 Stuffing Box Packing Replacement Refer to the Stuffing Box Assembly and Discharge/Connection Box Assembly drawings.

1. Referring to the Discharge/Connection Box Assembly drawing, remove the bellows hose clamp at the gland retainer and slide the bellows up the shaft.

2. Remove the stuffing box gland capscrews and hex nuts with washers and raise the gland retainer high enough to allow removal of the stuffing box bushing, packing and stuffing box spacer.

3. Remove the stuffing box bushing from the stuffing box housing, sliding it up the shaft.

4. Remove the packing.

5. Remove the stuffing box spacer from the stuffing box housing, sliding it up the shaft.

NOTE: Removal of the shaft scraper requires disassembly of the discharge/connection box assembly.


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Figure 5.19-3

Shaft Capscrew Hex nut

Washer Stuffing box housing Gland retainer

Stuffing box bushing Compression packing Stuffing box spacer

Grease fitting Shaft scraper

6. Thoroughly clean out the stuffing box housing.

7. Slide the stuffing box spacer down into the stuffing box housing.

8. Wrap the compression packing around the shaft and measure and cut the new packing carefully at a 45o angle so that ends will butt squarely at the joint when the packing is installed.

9. Insert the packing without stretching or twisting them.

10. Stagger the joints 90° apart so they will not line up and use the stuffing box bushing and gland retainer to press the packing into place.

11. Install the stuffing box bushing in the stuffing box housing.

12. Install the stuffing box gland retainer, using the capscrews, nuts and washers specified.

13. Tighten the capscrews and hex nuts finger tight.

14. Torque tighten the capscrews and nuts to compress the packing and produce a seal on the shaft, as specified on the Stuffing Box Assembly drawing.


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Figure 5.19-4

Step 1 Step 2 Step 3

Mark For Cutting (Joint) Cut On 45 For Overlap Joint 45°

Gasket Must Butt Squarely At Joint

15. Lubricate the stuffing box, referring to the Lubrication instructions on a previous page.

16. Attach the bellows to the gland retainer, using the hose clamp specified on the Discharge/Connection Box Assembly drawing.

5.20 Fastener Torque Specifications Use the Turn-of-Nut Method, see the table below, to tighten all High Strength Bolts to the required torque value after proper snug tightening. Do not reuse the High Strength Bolts.

Bolt Length Disposition of Outer Faces of Bolted Parts

As measured from underside of head to extreme end of point.

Both faces normal to bolt axis.

One face normal to bolt axis and other face sloped not more than 1:20 (bevel washer not used)

Both faces sloped not more than 1:20 from normal to bolt axis (bevel washers not used)

Up to and including (4) diameters

1/ 3 turn ½ turn 2/3 turn


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Bolt Length Disposition of Outer Faces of Bolted Parts

Over (4) diameters but not exceeding (8) diameters

½ turn 2/3 turn 5/6 turn

Over (8) diameters but not exceeding (12) diameters

2/3 turn 5/6 turn 1 turn

Nut rotation is the rotation relative to the bolt, regardless of the element (nut or Bolt). The Tolerance on rotation is 30° over or under.

Tighten all other fasteners according to the Torque Values drawing in the drawings section of this manual. Note that all torque values for the fasteners are for clean dry threads.


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Chapter 6: Operation

6.1 Flotation Mineral froth flotation is the most important mineral processing technique available today. In flotation, gas bubbles produced by the mechanical agitation of the mechanisms are used to float the mineral particles, through adhesion, to the surface of the cells for recovery.

Basically, the adhesion of the small particles to the gas bubbles reduces the specific gravity of the combined mineral-air particles so that the specific gravity of their association is less than the specific gravity of the pulp, so they are induced to rise in the pulp.

6.2 WEMCO® Flotation Machines Refer to the Mechanism Assembly drawings in the drawing section of the manual.

The SmartCell flotation machine is a unique design with a patented rotor-disperser that delivers intense, mixing and aeration. Ambient air is drawn into the cell and uniformly distributed throughout the pulp, providing optimum air/particle contact. A conical draft tube channels the flow for high pulp recirculation.

The combination of efficient aeration and optimum solids suspension gives high specie recovery and concentrate grade performance, while reducing reagent consumption. Easy start-ups, simple operation, low reagent consumption, long mechanism life and less required maintenance are features of the WEMCO flotation machines.

The WEMCO Flotation Cell Model Number is also the size of the cell tank. So, the Model 160 Cell is a cylindrical tank with nominal 160 m3 volume capacity. It features a proven WEMCO bearing housing and shaft drive mechanism, a conical draft tube for improved circulation, froth crowders to accelerate surface movement of solids, a feed box for better feed solids distribution, and connection and discharge boxes with dart valves for level control.

The flotation cell, consisting of the cylindrical tank and drive assembly, is the basic module of the WEMCO system. The cells are connected together and arranged in rows of cells. The cells are arranged in elevated steps for gravity flow of the pulp through connection/discharge boxes with dart valves, as shown on the Re-Cleaner Assembly drawing.

The cylindrical tank shape improves mixing and air distribution because all points on the tank periphery are equidistant from the rotor discharge. The corner between the bottom and sidewall is beveled.

The WEMCO bearing housing and shaft assembly is the heart of the drive assembly. It has a massive cast-iron bearing housing to maintain accurate shaft alignment under all loads and


Contents 74

moments. The rotor shaft is shorter than bottom agitated, forced air machines, which also contributes to this mechanism's long service life.

The rotor position, which is well above the tank bottom, eliminates contact with abrasive, oversize tramp material, thereby reducing wear on the rotor and disperser surfaces. Induced airflow into the pulp by the turning rotor provides efficient aeration.

Air control consists of a pipe with a manual butterfly valve on each cell. It admits the air, induced by the turning rotor, into the pulp where it is thoroughly dispersed through the pulp in the form of bubbles that attach themselves to the particles for the flotation. The induced airflow provides efficient aeration with mechanical simplicity.

The elevated rotor also allows cells to restart instantly after a shutdown, unlike forced-air systems with rotors. And, it can be restarted under full load. Mechanism erosion is further reduced by large clearances between the rotor and disperser.

The standpipe and crowder assembly modifies the movement of the froth and gives the froth a velocity component in the direction of the collection launder. The standpipe is the component of the mechanism that is provided to control air intake and stabilize the slurry vortex that forms around an operating rotor. The froth crowder accelerates movement of the froth across the surface of the tank, reducing residence time in the froth phase and the air input required for froth support. The shortened recovery period means energy savings, increased recovery and improved grade.

The draft tube promotes the circulation and suspension of solids in the flotation cell by drawing the pulp from the tank bottom up the draft tube into the rotor, where the pulp is mixed with air and pumped back out into the cell. Draft tubes are noted for their efficiency of mixing. The conical bottom increases circulation at the periphery of the tank.

False bottom design manages coarse particles. All of the pulp circulates up through the draft tube. The false bottom increases the velocity of the pulp as it flows along the bottom to be drawn up into the draft tube.

Lip length of internal froth launder relates directly to froth removal. The lip length of a round cell is longer than the launder of an equivalent volume rectangular unit.

Circular Connection boxes are the means for level control and even flow between cells. Dart valves in the connection box maintain the pulp level in the flotation cells by controlling the flow between cells.

The Circular Discharge box maintains the pulp level in the final cell in the row and provides a connection to the tailing sump.

Dart valves are located in the connection and discharge boxes; they are used to control the flow of pulp between the cells and from the discharge box. The valves are raised and lowered by SMC actuators with positioners that receive signals from the level controls, as described below.


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6.3 Level Controls Pulp level in the flotation cells is controlled by the automatically operated dart valves, located in the connection boxes and ending with the discharge box.

Level control is absolutely essential for good cell flotation performance. The level sensors come pre-calibrated for an indicated range and should only be adjusted by qualified personnel. As originally specified, these are all highly reliable electronic devices and if kept clean and not abused, should function well for extended plant service.

The float with the target plate attached to it above the surface rises and falls with the surface.

The Ultrasonic sensor sends a signal to the target plate and receives the reflected signal back. The signal from the Ultrasonic sensor goes to the controller which sends a signal to the pneumatically actuated dart valves that open and close to maintain the pulp level.

6.3.1 Dart Valves The valves control the flow of pulp through the flotation cells to maintain pulp level. The valves are actuated by rods from the positioners, which move the valves up and down in circular seats at the bottoms of the connection and discharge boxes.

If a dart valve does not seat closed when the actuator shaft is stroked to the full up position, then a mechanical adjustment can be made. The level control is not the way to adjust the valves.

During plant shut downs, the dart valve darts and circular seats should be checked for wear. The seat of the dart valve is subject to high abrasion and will require periodic replacement. Refer to the Maintenance instructions.

The Dart valves are controlled by the actuator assemblies. Qualified instrumentation technicians should be available to check the function of the actuator assembly components and calibrate as necessary.

The dart valves will fail closed upon loss of air by means of the back-up air supply.

6.4 Start-up and Operation 1. Before the flotation begins, make a general inspection.

• Check for any loose nuts and bolts.

• Verify that all belts are tensioned and all cover guards are in place.

• Verify that all power and instrument air connections are secure.

• Check for and remove any debris from the tanks, feed boxes and connection/discharge boxes, and from the walkways, platforms and stairways.


Contents 76

2. Turn on the power on for all the instrumentation and level controls.

3. Close the dart valves. The dart valves are normally in the UP position when the cells are shut down.

4. Fill the cells with slurry or water to operating depth. The mechanism normally should not be operated while filling the cell (see step 5).

• If the cells have substantial sand in the bottom there will be no problem starting the mechanism; however, it may take about an hour to re-suspend all of the solids.

5. Although the mechanisms can be started at anytime, pumping will not start until the pulp level is near the top of the draft tube.

6. Start the rotors when the slurry level is even with the top row of holes in the mechanism disperser.

NOTE: Operation of the mechanism when the cells are being filled with reagentized slurry can produce an extremely deep froth and excessive flow into the froth launders, as the slurry level is raised to the optimum operating depth.

7. Check the flow of froth over the weirs. Adjust weir height, as required, using the weir clips.

8. Adjust the pulp operating level to provide for the expected froth level. Refer to the manufacturer's instructions for adjustment of operating level with the level sensors and dart valves.

9. Check for seal and box leakage. Minor leakage may occur at the bolted connections at first, but the leakage should stop when sealed off by the fine solids in the pulp.

10. Adjust reagents (collector and frother) and air intake to provide the desired froth character and overflow rate.

11. Use a minimum of rinse water in the concentrate launders as this increases the volumetric flow to the next stage, increasing dewatering problems and reducing retention time in subsequent stages.

12. Sometimes extreme surging (increases) of flotation feed slurry is experi¬enced during the initial hours or days of operation because of unsteady unit operations upstream from the flotation circuit.

The controller settings should not be changed for fast surge relief, as this will result in poor control during normal operation, long after the feed surging problem is solved.

13. When the operation of the cell is smooth and the metallurgy is acceptable, refrain from making adjustments.

14. Operate the circuit consistent with management philosophy and instructions on all shifts. Changing operating strategies is a major source of losses in recovery and is a disruption to steady state operation.

15. Always operate with safety in mind and the objective of achieving quality production.


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6.5 Shutdown

6.5.1 Planned Shutdown (for cell inspection or maintenance) 1. Turn off the feed to the cells.

NOTE: Upon shutdown, the dart valves close, keeping the slurry in the cells. Refer to Unplanned Shutdown below.

2. Once the feed has been turned off, adjust the level control to slowly drain all of the cells.

NOTE: Do not open the dart valves to their fullest extent, as this can cause flooding downstream.

3. Shut off the mechanism when the rotor is no longer submerged in the pulp, as there is no need to operate the rotor since it will not continue to mix.

4. Once the cells are empty, check for sanding in the cells and the feed, connection and discharge boxes.

5. Clean out any areas of sanding that might cause problems for the next start-up.

6. The shutdown is complete, all power can be shut off.

7. Check the mechanisms. Report items that are in need of repair immediately to the supervisor as soon as discovered.

WARNING: Lock out the power if any maintenance or repairs will be performed.

6.5.2 Unplanned Shutdown When an unplanned shutdown occurs, turn off the power for the mechanism motors and controllers to avoid an unexpected start-up. Dart valves will normally fail in the Up (closed) position. At this point it will need to be determined if the pulp is to remain in the cell or if it should be drained.

1. Manually drain the cells, if required.

2. Once the cells are empty, check for sanding in the feed, connection and discharge boxes. Clean any areas of sanding that might cause problems for the next start-up.

NOTE: If the cells have substantial sand in the bottom there will be no problem re-starting the mechanism; however, it may take about an hour to re-suspend all of the solids.

3. Report items in need of repair immediately, as soon as discovered.


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Chapter 7: Troubleshooting

Problem Possible Cause Corrective Action

1. Motor does not start

a. No electrical power to motor

1. Check electrical breaker for ON

2. Check with voltmeter for power to motor

3. Check emergency stop, if furnished

b. Motor locked or bound

1. Remove V-belts and turn motor shaft by hand WARNING: Lock out power

2. If motor won't turn by hand, refer to Motor Manufacturer's Instructions

3. Replace the motor

c. Mechanism rotor locked or seized

1. Remove V-belts and turn driven sheave by hand WARNING: Lock out power to motor

2. If sheave will not turn, remove the mechanism and refer to the Maintenance Instructions for bearing replacement

2. Motor stops during operation

a. Loss of electrical power

1. Check power source

2. Check with voltmeter for power to motor

3. Check control fuse; see 2. c. below

b. Motor starter "trips" OFF

1. Ambient temperature at motor too high; see "3. Motor runs hot"

2. Voltage too low; check supply voltage, also check motor requirement on nameplate

3. Check amperage under load; may need to replace motor

4. Check starter box for properly sized heaters

c. Motor control fuse 1. Check for overheating of motor; see "3. Motor runs hot"

2. Check for motor overload; refer to Manufacturer's Instructions

3. Motor wires for wrong voltage; check line voltage with nameplate voltage; see "3." below

4. Check wiring to motor for proper hookup

3. Motor runs hot a. Motor overload 1. Check amperage through wires with full

load rating on nameplate

2. Check electrical source and wiring


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b. Inadequate air flow to motor

1. Check air flow around motor; clean surface of motor for better heat transfer

2. Check that the motor fan is rotating and all blades are in good condition

c. Rotor RPM too high 1. Check shaft RPM with tachometer; belt sheave may be improper size according to factory recommendation for rotor RPM

d. Mechanical problems with bearing and shaft assembly

2. Refer below to "6."

3. Refer below to "5."

4. Grease leakage from bearing housing (top and/or bottom bearings)

a. Overly lubricated bearings

1. Remove grease flushing plug whenever lubricating a bearing; reinstall plug when grease heats up WARNING: Do not replace plug while drive is running

2. Pump grease until fresh grease appears

b. Flushing plug is loose or not installed

1. Check flushing plug; it may not have been reinstalled after

2. Problem may be grease seal; see below

c. Grease seal has failed

1. No action, as seals may discharge excess grease when temperature of housing assembly rises; not a seal failure

2. Excessive leakage at start-up indicates seal cut or damaged during installation; replace seal referring to "Seals" in Maintenance

d. Grease too light for operating conditions

1. Use grease of higher viscosity; high heat has reduced viscosity, causing leakage. Refer to the Lubrication instructions

2. Refer to "4.a." above for overly lubricated bearings

5. Drive housing and bearings running hot [Note: Bearings are designed to run continuously at temperatures up to 82° C (180° F)]

a. Overly lubricated bearings

1. Too much grease can cause the bearings to generate too much heat; see "4. a. Overly lubricated bearings" above

2. May require no action, as bearings will run cooler after excess grease escapes

b. Bearings need lubrication

1. See "6.a." below


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c. Bearing beginning to fail

1. Confirm failing bearing, referring to "Bearing failing" below "6." below

2. Keep bearing lubricated for balance of its life, but be prepared to replace it any time due to complete failure

d. Ambient temperature too hot

1. Keep housing clean for good heat dissipation from surface

2. Try shade, but bearings will normally run hot during extremely hot days

3. May need to lubricate more often or use grease of higher viscosity

e. Belt tension too high 1. Check belt tension and adjust, if necessary, referring to the Installation and Maintenance instructions

6. Drive is unusually noisy and/or vibrating excessively

a. Bearings need lubrication

1. Bearings require lubrication at proper intervals; see Lubrication Instructions

2. Use correct viscosity grease; see Lubrication instructions

3. Motor needs lubrication or a bearing is failing; see Manufacturer's Instructions

b. Bearing failing causing excessive vibration

1. Rollers and races are rough and flaking causing excessive vibration; failure not too far off; replace bearings as soon as possible

2. With rotor stopped, shake rotor for excessive play to confirm failure WARNING: Lock out power to motor

3. Refer to Maintenance for bearing replacement

c. Rotor out of balance or contacting other components, or large rocks or other objects trapped in the draft tube

1. Stop rotor; check for missing vane or contact with other component, such as, disperser WARNING: Lock out power

2. If a vane is missing, replace the rotor

3. If another component is loose and contacting the rotor, repair or replace

4. Check for foreign material trapped inside the draft tube

5. Refer to Maintenance for repair or replacement

d. Loose bearing, excessive end play

1. Depending on bearing/shaft assembly model, check for loose end caps or check for shaft end play

2. Refer to the Maintenance Instructions


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e. Misalignment of the sheaves

1. Check run-out at the outer diameter of the sheave using a dial indicator

2. Check to be sure motor shaft is parallel to the rotor shaft

3. Check that both the driven and driver sheaves are parallel

7. Rotor does not turn when electrical power is ON

a. Motor does not run 1. Refer to Problems "1. Motor does not start" & "2. Motor stops during operation"

b. Drive belts extremely loose or separated

1. Check belts to be sure they are intact

2. Check belts for tension; see Maintenance Instructions for tensioning WARNING: Lock out power

c. Rotor shaft broken 1. Check rotor shaft

8. RPM of rotor below rated design, affecting product

a. Drive V-belts are loose and slipping

1. Squealing belt is a slipping belt; tension the belts; see Maintenance

2. New belts stretch and need re-tensioning

3. Install new belts

b. V-belt drive ratio too large

1. Check sheave sizes with design specification

2. Check that belts fit groove of sheaves

c. Motor overload 1. See Problem "3. Motor runs hot" items "a." and "c."

9. Tank leaks

a. Damage or gaps in internal coating allowed accelerated corrosion

1. Repair leaking area by patching and welding; WARNING: Use experienced welders and lock out power to the drive

2. Recoat the surface with specified coating

10. Unplanned shut down

a. Loss of electrical power

1. Dart valves will normally fail open and drain cells to reduce sanding; to keep cells from draining, manually close dart valves but allow some flow to reduce sanding

2. Lock out power to prevent accidental start-up when power resumes; perform maintenance as required

3. Check for sanding when cells are empty

b. Mechanical failure 1. Refer to "Shut down" in Operating Instructions

2. Lock out power before starting repairs

3. Plan shut down for maintenance before an equipment failure occurs


Contents 82


c. Loss of feed 1. Continue operating until drop in level prevents normal operation, then shut down

2. Short down time, add water to maintain operation

11. Cell does not produce froth or flotation bubbles

a. Rotor is not turning when electrical power is ON

1. See Problem "7."

b. Air inlet is plugged 1. Air piping has obstructions. Clean air piping

2. Air control valve is closed. Open air control valve

c. Part or all the disperser has broken away from its ring under the standpipe

1. Pull mechanism and replace or reattach the disperser; see Maintenance

2. When disperser is installed, make sure it is correctly installed and the fasteners are secure

d. Rotor has broken loose or lost some of its vanes

1. Remount rotor; a disconnected rotor would occur from improper installation; refer to Maintenance Instructions for correct installation

2. Replace rotor if damaged; a damaged rotor would vibrate excessively; see Problem "6."

12. Pulp overflowing with froth

a. Pulp [slurry] level is too high in cell

1. Level of weir for pulp operating level may need adjustment for desired froth depth

2. Level control setpoint needs adjusting for operating level; see Operation and level control Manufacturer's Instructions

3. Check the dart valves, may be manually closed; open valve; check air lines to valve actuators

4. Check dart valve control; may not be functioning properly for pulp level; check output to I/P and signal to actuator; see Controller Instructions

b. Feed rate may be excessive

1. Check discharge box discharge flow rate; if rate is high then decrease feed rate

2. No action, since surge flows may occur during first days of operation due to unsteady operations upstream

3. Check flow rates of connection and discharge boxes that would indicate dart valve malfunction; see above


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c. Controller setpoint not reset for proper level after temporary change

1. Reset controller setpoint; controller settings should not be changed for temporary feed surge relief

2. Recheck setpoint for proper setting

13. Froth recovery poor, not up to requirements

a. Pulp level is too low in cell for froth level

1. Low feed level or no feed; check flow rate

2. Weir level too low for required depth of froth; adjust level upwards

3. Controller setpoint too low for dart valve position; increase setpoint for desired froth depth

b. Air control plugged or not adjusted correctly

1. Remove any accumulations of solids around the air intake; see Maintenance

2. Try increasing the air intake into the standpipe; make sure intake is clear

c. Washwater rate too high

1. Launder wash should be decreased or intermittent to reduce dilution of froth

2. Water supply pressure too high; reduce pressure

3. Replace water valve seals, adjust shut off solenoid or adjust controller timer (as furnished); refer to Manufacturer's Instructions; do maintenance

d. Chemical reagent and/or frother not correct for pulp

1. Dosage not optimal or correct; bench tests required to determine effective reagent or frother and correct amounts of each

2. Check air intake; see above

3. Feed composition has changed; need more frequent evaluation for dosage of chemicals

4. Reduce feed flow through cells; it is greater than optimal rate for desired froth

e. Mechanical problem with rotor mechanism or mechanism not operating at optimum

1. RPM of rotor needs to be increased; see Problem "8. RPM of rotor below rated design, affecting product

2. See Problem "11. Cell does not produce..."

3. Check if mechanism is vibrating, reducing mixing ability; see Problem "6."


Contents 84


14. Liquid level varies from original setting

a. Level controller malfunction

1. Refer to Controller Manufacturer's Instructions for operation and maintenance

2. Check dart valves for response to controller; refer above for controller; refer below for valves

b. Dart valves not operating properly

1. Check movement of valve shafts; jerky movement indicates alignment or corrosion problem, see Maintenance; no action indicates controller problem, see item "a." above

2. Check for air leaks to valves; check for adequate air actuation pressure; see Maintenance

3. Dart valves may be leaking at grommets due to excessive wear; refer to Maintenance

4. Valves normally open at loss of power; check for closed valves

5. Check control air supply pressure

6. Check air signal to positioner to ensure it is giving the positioner the correct signal

c. Controller inadvertently reset for wrong setpoint after temporary change

1. Reset for correct setpoint

2. Avoid changing setpoint for temporary changes in pulp flow

15. Sanding in cells and boxes

a. Accumulated sand in connection boxes

1. Keep dart valves partially open during start-up to allow flow through

2. Check valves for actuation; refer to Problem "14." cause item "b."

b. Accumulated sand in cell

1. Restart rotor; it will start despite sand in bottom of cell; rotor will gradually re-suspend the sand

2. Drain the tank in case of an extended shut down

3. Check up stream process; feeds with excessive course solids are sometimes difficult to keep in suspension

c. Mechanism problem prevents adequate mixing of feed and suspension of solids

1. Refer to Problem “13.” Cause item “e.”

2. Refer to the Maintenance instructions


Contents 85

Chapter 8: Final Mechanical Checklist

8.1 SERIAL NUMBER: CSP0000671-03A Sign off by initialing and dating each check made. When the final mechanical check is completed, both the FLSmidth serviceman and the installer/erector must sign and date this CHECK LIST, and return one copy of this CHECK LIST for each WEMCO® flotation cell furnished to the FLSmidth Project Management Department to ensure warranty coverage.

CHECK REFERENCE INSTALLER SIGN OFF FLSmidth SERVICEMAN

SIGN OFF

TANK INSTALLATION

Check tank support beams for level within ± 3 mm (1/8”)

General Arrangement and Re-Cleaner Assembly drawing, and Installation instructions in the FLSmidth instruction manual

Check tank, feed boxes, connection boxes, discharge box and linings for damage

Installation and Maintenance instructions in the FLSmidth instruction manual

Check tank-to-tank connections for proper gasketing

Re-Cleaner Assembly drawings, Parts List and Installation instructions in the FLSmidth instruction manual

Check tank-to-tank fasteners for proper torque

Installation instructions in the FLSmidth instruction manual

TANK ASSEMBLY

Check each tank for level


Check tank-to-tank connections for leakage after start-up


Check draft tube and false floor for specified concentricity with rotor



Contents 86


SIGN OFF

FEED, CONNECTION AND DISCHARGE BOXES

Check box-to-tank flanged connections are properly secured


Check for proper seating of dart valves in dart valve seats (gromments)

Assembly drawings and Installation instructions in the FLSmidth instruction manual

Check the dart valve shaft is in alignment


Check controls for proper installation

Installation and Operation instructions in the FLSmidth instruction manual

Check for specified air supply pressure


Check dart valves for smooth operation


Check dart valves stuffing boxes for proper lubrication


MECHANISM ASSEMBLY

Check mechanism (rotor) shaft for plumb

Assembly drawings and Installation and Maintenance instructions in the FLSmidth instruction manual

Check motor-to-motor bracket connection for specified fasteners

Mechanism Assembly drawings and Installation and Maintenance instructions in the FLSmidth instruction manual


Contents 87


SIGN OFF

Check motor-to-motor bracket fasteners for specified torque


Check motor bracket-to-bearing stand connection for specified fasteners


Check motor bracket-to-bearing stand connection fasteners are secure


Check motor support bracket-to-motor mounting plate connection fasteners are secure


Check sheaves for alignment


Check V-Belt tension Installation and Maintenance instructions in the FLSmidth instruction manual

Check motor wiring Manufacturer’s instructions in the Accessory Equipment Section of the FLSmidth instruction manual

Check rotor shaft bearings have been properly lubricated

Lubrication instructions in the FLSmidth instruction manual

Check motor for specified direction of rotation

General Arrangement and Assembly drawings, and motor manufacturer’s instructions in the Accessory Equipment Section of the FLSmidth instruction manual


Contents 88


SIGN OFF

Check the belt guards have been installed properly

Assembly drawings, Parts List and Installation instructions in the FLSmidth instruction manual

LEVEL FLOAT ASSEMBLIES

Check the level float assemblies for proper installation


Check level float assemblies for smooth operation


Check sonic level detectors for operation

Manufacturer’s instructions in the Accessory Equipment Section of the FLSmidth instruction manual

INSTRUMENATION AND CONTROLS

Check level control system wiring and pneumatic piping

Manufacturer’s instructions in the Accessory Equipment Section of the FLSmidth instruction manual (if furnished by FLSmidth)

MISCELLANEOUS

Check froth sensors for operation


Check all WARNING and CAUTION signs are properly installed and clearly visible and readable

Assembly drawings and installation instructions in the FLSmidth instruction manual


Contents 89


SIGN OFF

NOTES AND COMMENTS

(Installer/Erector) (Date)

(FLSmidth Service Representative) (Date)


Contents 90

8.2 SERIAL NUMBER: CSP0000671-03B Sign off by initialing and dating each check made. When the final mechanical check is completed, both the FLSmidth serviceman and the installer/erector must sign and date this CHECK LIST, and return one copy of this CHECK LIST for each WEMCO® flotation cell furnished to the FLSmidth Project Management Department to ensure warranty coverage.


SIGN OFF

TANK INSTALLATION









TANK ASSEMBLY











Contents 91


SIGN OFF













MECHANISM ASSEMBLY








Contents 92


SIGN OFF


















Contents 93


SIGN OFF











MISCELLANEOUS






Contents 94


SIGN OFF

NOTES AND COMMENTS




Contents 95

8.3 SERIAL NUMBER: CSP0000671-03C Sign off by initialing and dating each check made. When the final mechanical check is completed, both the FLSmidth serviceman and the installer/erector must sign and date this CHECK LIST, and return one copy of this CHECK LIST for each WEMCO® flotation cell furnished to the FLSmidth Project Management Department to ensure warranty coverage.


SIGN OFF

TANK INSTALLATION









TANK ASSEMBLY











Contents 96


SIGN OFF













MECHANISM ASSEMBLY








Contents 97


SIGN OFF


















Contents 98


SIGN OFF











MISCELLANEOUS






Contents 99


SIGN OFF

NOTES AND COMMENTS




Contents 100

Chapter 9: Appendices

9.1 Drawing List Drawing Title Drawing Number Rev Level

Top Level CSP0000671-03 2

General Arrangement 633600 5

Single Tank General Arrangement

633601 4

Connection Discharge Box General Arrangement

633605 3

Instrumentation Provisions and Requirements

633602 8

Anchor Chair Layout and Foundation Loads

633603

6

Mechanism Assembly 644564 1

Re-Cleaner Assembly 644555 1

Tank Type I Assembly 644556 1

Radial Launder, Weir and Baffle Plate Assembly

644563 1

Radial Launder Assembly 615654 2

Tank Type II Assembly 644557 1

Tank Type III Assembly 644558 1

Bearing Housing Assembly 612649


Contents 101

Drawing Title Drawing Number Rev Level

Air Control Assembly 602750 2

Belt Guard Assembly 624243 1

Belt Guard Top Assembly 624240 1

Connection Box Assembly 654945 1

Stuffing Box Assembly 1108628-01 1

Connection Box Assembly 654946 1

Discharge Box Assembly 654947 1

Level Sensor Assembly 654948 1

Froth Sensor Assembly 617606 1

Platform Assembly 653201 1

Stairway Assembly 653210 1

Re-Cleaner Row Cable Tray Assembly

655760 1

Interconnecting Stairway Assembly

644539 1






Torque Values 114808 4