AAC Kemix Pumpcell Plant Operating Installation Manual - Yamana - Chile Minera Florida Limitada Project - Rev0

Kemix Pty Ltd AAC Pumpcell Plant Operating Manual
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KEMIX (Pty) Ltd
Reg. No. 1989/003259/07

Incorporating

STALLION MIXERS
47 Kyalami Boulevard,
Kyalami Business Park,
PO Box 31949, Kyalami, 1684
SOUTH AFRICA
Tel. (+27 11) 466-2490
Fax. (+27 11) 466-2190
email: kemix@kemix.com
web site: www.kemix.com

AAC Pumpcell Plant
Operating and Maintenance Manual

Client YAMANAGOLD - MINERA FLORIDA LIMITADA
Project MINERA FLORIDA LIMITADA PROJECT - CHILE
Equipment 1 x 135m
3
, 8 STAGE PUMPCELL PLANT
INCLUDING MPS0470(P) INTERSTAGE SCREENS
Contract Number E70444/2011
Date 28
TH
JULY 2011
Revision 0


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Table of Contents

1 CONTACT DETAILS ....................................................................................................... 1
2 INTRODUCTION .............................................................................................................. 2
2.1 AAC Pumpcell Description ........................................................................................ 2
2.2 AAC Pumpcell Process Description .......................................................................... 5
2.3 AAC Pumpcell Control Systems and Philosophies .................................................... 6
2.3.1 Pumpcell Plant Start Up ................................................................................. 6
2.3.2 Lead Pumpcell Isolation ................................................................................. 9
2.3.3 Pumpcell Drainage ....................................................................................... 10
2.3.4 Tail Pumpcell Sequencing ........................................................................... 10
2.3.5 Pumpcell Bypassing..................................................................................... 11
2.3.6 Regenerated Carbon Return ........................................................................ 12
2.3.7 Plant Stoppage ............................................................................................. 13
3 AAC PUMPCELL DATA SHEET ................................................................................... 14
4 SPARE PARTS .............................................................................................................. 15
4.1 Spare Parts Numbering Designations ..................................................................... 15
5 UNPACKING AND ASSEMBLY PROCEDURE AFTER TRANSPORTATION. ............ 18
5.1 Step 1 - Removal of the Rotating Cage Support A-Frame ...................................... 18
5.2 Step 2 - Removal of the front 1st shaft Locking Brackets ........................................ 21
5.3 Step 3 - Removal of the Pump Support Brackets. ................................................... 22
5.4 Step 4 - Removal of the Rotating Cage Locking Brackets ....................................... 24
5.5 Step 5 Assembly of the Kemix Interstage Screen from the Transported State of
Partial Assembly ................................................................................................................ 26
6 COMPLETE BREAKDOWN OF MECHANISM FOR ASSEMBLY ................................ 27
6.1 Pre-Assembly requirements 1 to 8 .......................................................................... 27
6.1.1 Pre-Assemble 1: the Pulse Blades to the Rotating Cage ................................ 27
6.1.2 Pre-Assemble 2: the Hydraulic Leg to Screen ................................................ 29
6.1.3 Pre-Assemble 3: the Female Rigid Coupling to the Gearbox Output Shaft ..... 31
6.1.4 Pre-Assemble 4: the Gearbox to Base Plate .................................................. 32
6.1.5 Pre-Assembly 5: Assemble the pump ............................................................. 34
6.1.6 Pre-Assembly 6 Assemble the pump coupling to the first shaft ................... 36
6.1.7 Pre-Assemble 7: Agitator Blades to agitator shaft........................................... 37
6.1.8 Pre-Assemble 8: Volute Interface Seal to Volute ............................................ 38
6.2 Position the Volute into the maintenance structure ................................................. 39
6.3 Position the Pumping Impeller into the Volute ......................................................... 40
6.4 Assemble the 1
st
Shaft into Pumping Impeller ......................................................... 42
6.5 Position the Internal Frame Into the Volute ............................................................. 44
6.6 Assemble the Gearbox and Base Plate Assembly onto the Internal Frame ............ 46
6.7 Assemble the Gearbox coupling onto the 1
st
Shaft ................................................. 48
6.8 Assemble the Hydraulic Leg and Screen Assembly to the Volute ........................... 50
6.9 Assemble the Rotating Cage to the 1
st
Shaft .......................................................... 52
6.10 Assemble Agitator to the Mechanism ...................................................................... 54
7 CHECKING AND ADJUSTMENT OF THE MPSP INTERSTAGE SCREEN BEFORE
OPERATION.......................................................................................................................... 55
7.1 Perform Alignment Checks on Shaft and Rotating Cage ......................................... 56
8 INSTALLATION AND REMOVAL OF AN AAC PUMPCELL INTERSTAGE SCREEN . 57
8.1 Installation ............................................................................................................... 57
8.1.1 Open Hook Mounting Bracket and Hold Down Clamp .................................... 57
8.1.2 Lower And Position The Mechanism In The Tank ........................................... 57
8.1.3 Position And Secure The Mechanism ............................................................. 57

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8.1.4 Adjusting the Hook Mounting bracket ............................................................. 57
8.1.5 Tighten Hook Mounting Bracket and Hold Down Clamp ................................. 58
8.2 Removal.................................................................................................................. 61
8.2.1 Open Hook Mounting Bracket and Hold Down Clamp .................................... 61
8.2.2 Lift the Interstage Screen Out Of The Tank .................................................... 61
9 MAINTENANCE AND INSPECTION PROCEDURE ...................................................... 62
9.1 Maintenance and Inspection Procedure during normal operation ........................... 62
9.1.1 Maintenance and Inspection of the Wedge Wire Screen ................................ 62
9.1.2 Maintenance and Inspection of the Drive Unit. ............................................... 64
9.1.3 Maintenance and Inspection of the Protective coatings of Entire Interstage
Screen Assembly. .......................................................................................................... 64
9.2 Maintenance and Inspection Procedure during Storage .......................................... 65
9.2.1 Maintenance and Inspection of the Drive Unit during Storage ........................ 65
9.2.2 Maintenance and Inspection of the Entire Interstage Screen Assembly during
Storage 65
10 SPARES REPLACEMENT PROCEDURES .............................................................. 66
10.1 Wedge-Wire Screen Replacement .......................................................................... 66
11 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ELECTRIC MOTORS
69
11.1 Receiving Check ..................................................................................................... 69
11.2 Handling and Transportation ................................................................................... 69
11.3 Storage ................................................................................................................... 69
11.4 Insulation Resistance Check ................................................................................... 70
11.5 Installation ............................................................................................................... 70
11.5.1 Safety ............................................................................................................. 70
11.5.2 Operating Conditions ...................................................................................... 70
11.5.3 Foundation ..................................................................................................... 71
11.5.4 Drain Holes ..................................................................................................... 71
11.5.5 Balancing ........................................................................................................ 71
11.5.6 Alignment ....................................................................................................... 71
11.5.7 Belt Drive ........................................................................................................ 72
11.5.8 Connection ..................................................................................................... 72
11.5.9 Starting Methods ............................................................................................ 72
11.5.10 Start-Up ...................................................................................................... 73
11.6 Maintenance ........................................................................................................... 74
11.6.1 General Inspection ......................................................................................... 74
11.7 LUBRICATION ........................................................................................................ 74
11.7.1 Machines without Grease Nipples .................................................................. 74
11.7.2 Machines Fitted with Grease Nipples ............................................................. 74
11.7.3 Compatibility of Polyrex
EM grease with other types of grease ..................... 76

11.8 ASSEMBLY AND DISASSEMBLY .......................................................................... 76
11.9 SPARE PARTS ....................................................................................................... 77
11.10 MOTORS FOR HAZARDOUS LOCATIONS ........................................................... 77
11.10.1 Installation .................................................................................................. 77
11.10.2 Maintenance ............................................................................................... 77
11.11 MOTORS DRIVEN BY VFD .................................................................................... 78
11.11.1 Standard Motors ......................................................................................... 78
11.11.2 Inverter Duty Motors ................................................................................... 78
11.12 WARRANTY TERMS - SERIES AND ENGINEERING PRODUCTS ...................... 78
12 BOLT TORQUE TABLE ............................................................................................ 80
13 TOOLS REQUIREMENT............................................................................................ 80
14 TECHNICAL DRAWINGS 1 G.A OF AAC PUMPCELL PLANT ............................. 81
15 TECHNICAL DRAWINGS 1 G.A OF AAC PUMPCELL MECHANISM ................... 82

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16 TECHNICAL DRAWINGS 3 P & ID AND PFD ........................................................ 83
18 GEARBOX OPERATING INSTRUCTIONS ............................................................... 84
19 LUBRICATION SCHEDULE ...................................................................................... 85

Kemix Pty Ltd Interstage Screen Operating Manual

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1 CONTACT DETAILS

Kemix may be contacted directly at:

KEMIX HOUSE
47 KYALAMI BOULEVARD
KYALAMI BUSINESS PARK
MIDRAND
P O BOX 31949
Kyalami
1684
South Africa

Tel: (+27 11) 466-2490
Fax: (+27 11) 466-2190

Email: kemix@kemix.com


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2 INTRODUCTION
2.1 AAC Pumpcell Description

The ability of activated carbon to adsorb gold from a cyanide solution has been
known for over one hundred years. However, it was not until the 1950s that carbon
based processes began to attract attention in the gold mining industry, when it was
demonstrated by the US Bureau of Mines that gold and silver could be recovered
directly from pulp onto granules of activated carbon.

There are three basic carbon adsorption processes used in the gold mining industry
today, carbon in pulp (CIP), carbon in leach (CIL) and carbon in columns (CIC). The
first two processes recover gold directly from pulps or slurries containing up to 55 %
solids, while the CIC process is used for the treatment of solution.

Kemix (Pty) Ltd (Kemix) in conjunction with Anglo American Corporation (AAC)
developed the Mineral Processing Separating (MPS) and Mineral Processing
Separating (Pumping) (MPS(P)) Interstage Screens. The MPS and MPS(P)
Interstage Screens are typically utilised in CIP and CIL applications to separate
activated carbon from gold bearing pulp in leach or adsorption contactors.

The development of the MPS(P) Interstage Screen was instrumental in the ultimate
development of the AAC Pumpcell. The AAC Pumpcell is in essence a complete CIP
plant incorporating a Pumpcell mechanism and launder system enabling the carousel
mode of operation to be employed.

The design of the AAC Pumpcell circuit allows for all contactors to be placed at the
same evaluation, in contrast to the stepped arrangement used for conventional
cascade CIP adsorption plants. This feature facilitates the carousel mode of
operation, that is the pulp feed and tailings discharge positions are rotated in such a
manner that a counter current movement of pulp and carbon is achieved without the
need to physically move carbon from one Pumpcell to another. The carousel mode of
operation has been shown to result in significant improvements in adsorption
efficiency, due to the elimination of 'backmixing' inherent in the conventional CIP
circuits.

The Pumpcell mechanism consists of a drive unit combining the three functions of
pumping, screen cleaning and agitation on one common drive shaft.

The pumping impeller is a mixflo type specially designed to handle high flowrates at a
low tip speed. The up-pumping impeller operates in a stable manner over a wide
range of flow conditions. The up-pumping impeller develops a head in the open
volute, which is connected to the internal launder, sufficient to overcome launder
losses and allows for the velocity flow of pulp to the next contactor.

The pitch blade turbine ensures that pulp contained within the screen is maintained in
a fully suspended state even when there is no pulp flow through the mechanism. In
the event of a plant stoppage the pulp inside the screen may settle out, this pulp is
re-suspended when the drive unit is restarted. The Pumpcell mechanism can
therefore be operated at reduced pulp flowrates without the settling of pulp occurring
inside the cylindrical screen.


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The unique rotating cage sets up a pulse and sweeping action around the screen,
which keeps carbon off the screen. These features reduce the possibility of carbon or
grit pegging in the screen apertures, which in turn ensures that pulp flowrate through
the screen, is maintained.

The screen is manufactured from stainless steel wedge wire. Attached to the bottom
of the screen and around the shaft is a hydraulic seal. The hydraulic seal is a static
pipe which passes through the center of the pumping impeller extending up beyond
the pulp operating level thus forming a very effective seal which has no moving parts.

Attached to the bottom of the shaft is a down pumping hydrofoil. This hydrofoil is
situated in the cell to ensure that an efficient high velocity flow pattern is achieved
and maintained thus reducing the possibility to pulp and carbon settlement occurring
within the cell.

The Pumpcell tank comprises of an internal launder system, discharge and feed
pipes, launder gates and plug valves. The internal launder is arranged such that it
facilitates the individual functions of feeding pulp to the Pumpcell, discharging pulp
from the Pumpcell and bypassing the Pumpcell in the event of taking the particular
Pumpcell off line. This launder connects the adjacent Pumpcells together. The nature
of this launder arrangement enables the carousel mode of operation to be employed.

Figure 1 The AAC Pumpcell mechanism in a tank

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Figure 2 The Cross Section View of AAC Pumpcell mechanism


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2.2 AAC Pumpcell Process Description

Pulp should be screened either prior to or post the leach circuit to remove grit or
fibrous material present in the CIP feed. The screened pulp exiting the leach circuit
either gravitates or is pumped to the AAC Pumpcell feed launder.

The lead Pumpcell receives fresh pulp from the feed launder which is located above
the Pumpcell top platform. The feed launder valve arrangement directs the flow of
pulp into the desired Pumpcell. The pulp enters the Pumpcell via a feed box and feed
pipe and is directed to an area below the down pumping hydrofoil, thus reducing the
possibility of short circuiting. The down pumping hydrofoil imparts sufficient energy
into the pulp resulting in good mixing of the pulp and carbon which in turn results in
gold being adsorbed onto the carbon.

As all the Pumpcells are at the same horizontal elevation the cascade flow of pulp
between the individual Pumpcells is not possible. The movement of pulp between the
Pumpcells is effected by the Pumpcell mechanism. Pulp is drawn through the wedge
wire screen by virtue of the up-pumping impeller developing a head in the open
volute, which is connected to the internal launder. The head created is sufficient to
overcome launder losses and allows for the velocity flow of pulp to the next
Pumpcell. The wedge wire screen aperture is appropriately sized to allow for the flow
of pulp through the screen while ensuring that the carbon remains in the Pumpcell as
a discreet batch.

The pulp is pumped through all the stages in the Pumpcell circuit. The pulp exiting
the last Pumpcell in the carousel sequence is directed via a residue valve and
manifold to the residue linear or vibrating screen.

When the gold on carbon loading in the lead Pumpcell has reached the
predetermined value the lead Pumpcell is isolated and the feed material will be
directed to the second Pumpcell in the carousel sequence. The isolation of the lead
Pumpcell and direction of the feed to the second Pumpcell is achieved by opening
and closing the appropriate gate and plug valves. This procedure will be detained in
Section 2.3.2, Operating Philosophy. The second Pumpcell effectively becomes the
new lead Pumpcell.

The entire contents of the lead Pumpcell is drained and pumped via a recessed
impeller pump to the loaded carbon screen. The loaded carbon typically gravitates
into a loaded carbon hopper from where it is directed to the elution and regeneration
circuits prior to been returned to the Pumpcell circuit.

When the content of the original lead Pumpcell has been drained and the Pumpcell is
brought back on line as the new tail Pumpcell. Putting the original lead Pumpcell on
line as the new tail Pumpcell is achieved by opening and closing the appropriate gate
and plug valves and replenishing the Pumpcell with a predetermined amount of
regenerated or virgin carbon. This procedure will be detained in Section 2.3.4,
Operating Philosophy.

During the draining of the lead Pumpcell the entire Pumpcell plant operates with one
cell less in the carousel sequence. It is therefore prudent to get the original lead
Pumpcell back on line as the new tail cell in as short a time period as is practically
possible thereby not negatively impacting on the overall metallurgical performance of
the Pumpcell plant.

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2.3 AAC Pumpcell Control Systems and Philosophies
The Pumpcell operating philosophy will detail the procedure and valve sequencing
required when performing the following tasks :

Pumpcell Plant Start Up.
Head Pumpcell Isolation.
Head Pumpcell Drainage.
Tail Pumpcell Sequencing.
Pumpcell Bypassing.
Plant Stoppage.

For the purposes of this exercise Pumpcell No. 1, (922 TK 114), will be the head
Pumpcell and Pumpcell No. 8, (922 TK 107), will be the tail Pumpcell.

2.3.1 Pumpcell Plant Start Up

Prior to starting the Pumpcell plant, ensure that the residue section is prepared to
receive and dispose of pulp.
Identify which Pumpcell is to be the head, second, third, fourth, fifth, sixth,
seventh and eighth Pumpcells. For the purpose of this example Pumpcell 1,
(922 TK 114), will be the head Pumpcell and Pumpcell 8, (922 TK 107),
will be the tail Pumpcell.
Ensure that the predetermined amount of carbon is available to be added to each
Pumpcell once pulp has been introduced into the Pumpcell.
All Pumpcell drive motors must be stopped.
The manual loaded carbon drain diaphragm valves on all eight the Pumpcells
must be opened. The manual loaded carbon drain diaphragm valves to be
opened are (922 150 HD 107), (922 150 HD 207),
(922 150 HD 307), (922 150 HD 407), (922 150 HD 507),
(922 150 HD 607), (922 150 HD 707) and (922 150 HD 807).
The automated loaded carbon drain diaphragm valves on all eight the Pumpcells
must be closed. The automated loaded carbon diaphragm valves to be closed
are (922 150 HD 108), (922 150 HD 208), (922 150 HD 308),
(922 150 HD 408), (922 150 HD 508), (922 150 HD 608),
(922 150 HD 708) and (922 150 HD 808).
Open the automated feed plug valves on Pumpcell No. 2, (922 TK 113), to
Pumpcell No. 8, (922 TK 107), in the carousel sequence. The automated feed
plug valves to be opened are (922 300 KXHP 201),
(922 300 KXHP 301), (922 300 KXHP 401),
(922 300 KXHP 501), (922 300 KXHP 601), 922 300 KXHP 701)
and (922 300 KXHP 801).
Close the automated feed plug valve on the head Pumpcell, Pumpcell No. 1,
(922 TK 114).The automated feed plug valve to be closed is
(922 300 KXHP 101).
Open the manual Pumpcell Mechanism discharge gate valves on all eight the
Pumpcells. The manual Pumpcell Mechanism discharge gate valves to be
opened are (922 450 KXHG 106), (922 450 KXHG 206),
(922 450 KXHG 306), (922 450 KXHG 406),
(922 450 KXHG 506), (922 450 KXHG 606),
(922 450 KXHG 706) and (922 450 KXHG 806).
Close the automated residue plug valves on Pumpcell No. 1, (922 TK 114), to
Pumpcell No.7, (922 TK 108), in the carousel sequence. The automated
residue plug valves to be closed are (922 300 KXHP 102),

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(922 300 KXHP 202), (922 300 KXHP 302),
(922 300 KXHP 402), (922 300 KXHP 502),
(922 300 KXHP 602) and (922 300 KXHP 702).
Open the automated residue plug on the tail Pumpcell in the carousel sequence,
Pumpcell No. 8, (922 TK 107). The automated residue plug valve to be
opened is (922 300 KXHP 802).
Close the manual bypass gate valves on all eight the Pumpcells. The manual
bypass gate valves to be closed are (922 400 KXHG 104),
(922 400 KXHG 105), (922 400 KXHG 204),
(922 400 KXHG 205), (922 400 KXHG 304),
(922 400 KXHG 305), (922 400 KXHG 404),
(922 400 KXHG 405), (922 400 KXHG 504),
(922 400 KXHG 505), (922 400 KXHG 604),
(922 400 KXHG 605), (922 400 KXHG 704),
(922 400 KXHG 705), (922 400 KXHG 804) and
(922 400 KXHG 805).
Open the automated interconnecting tank gate valves on Pumpcells No. 1,
(922 TK 114) to Pumpcell No. 7 (922 TK 108) in the carousel sequence.
The automated interconnecting tank gate valves to be opened are (922 450
KXHG 103), (922 450 KXHG 203), (922 450 KXHG 303),
(922 450 KXHG 403), (922 450 KXHG 503),
(922 450 KXHG 603) and (922 450 KXHG 703).
Close the automated interconnecting tank gate valve on the tail Pumpcell,
Pumpcell No. 8, (922 TK 107), in the carousel sequence. The automated
interconnecting tank gate valve to be closed is (922 450 KXHG 803).
Open the automated feed launder plug valve feeding the head Pumpcell,
Pumpcell No. 1 (922 TK 114). The automated feed launder plug valve to be
opened is (922 250 KXHP 001).
Close the automated feed launder plug valves feeding Pumpcell No. 2,
(922 TK 113), to Pumpcell No. 8, (922 TK 107), in the carousel sequence.
The automated feed launder plug valves to be closed are
(922 250 KXHP 003), (922 250 KXHP 005),
(922 250 KXHP 007), (922 250 KXHP 009),
(922 250 KXHP 011), (922 250 KXHP 013) and
(922 250 KXHP 015).
Close all the automated feed launder isolation gate valves. The automated feed
launder isolation gate valves to be closed are (922 400 KXHG 002),
(922 400 KXHG 004), (922 400 KXHG 006),
(922 400 KXHG 008), (922 400 KXHG 010),
(922 400 KXHG 012) and (922 400 KXHG 014).
On completion of the above steps, the carousel valve sequencing can be
considered complete. Pulp can now be introduced into the Pumpcell plant.
The feed to the Pumpcell plant can be initiated.
When pulp enters the head Pumpcell, Pumpcell No. 1, (922 TK 114), in the
carousel sequence the predetermined amount of carbon is added to the
Pumpcell.
When the hydrofoil is submerged by pulp in the head Pumpcell, Pumpcell No. 1,
(922 TK 114), the Pumpcell Mechanism, (922 SC 114), drive motor must
be started.
When the pulp level in the head Pumpcell, Pumpcell No. 1, (922 TK 114),
approaches the same vertical elevation as the pumping impeller, pulp will be
pumped to the second Pumpcell, Pumpcell No. 2 (922 TK 113), in the
carousel sequence.

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When pulp enters the second Pumpcell, Pumpcell No. 2, (922 TK 113), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the second Pumpcell, Pumpcell No.
2, (922 TK 113), the Pumpcell Mechanism, (922 SC 113), drive motor
must be started.
When the pulp level in the second Pumpcell, Pumpcell No. 2, (922
TK 113), approaches the same vertical elevation as the pumping impeller, pulp
will be pumped to the third Pumpcell, Pumpcell No. 3 (922 TK 112), in
the carousel sequence.
When pulp enters the third Pumpcell, Pumpcell No. 3, (922 TK 112), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the third Pumpcell, Pumpcell No. 3,
be started.
When the pulp level in the third Pumpcell, Pumpcell No. 3, (922 TK 112),
pumped to the fourth Pumpcell, Pumpcell No. 4 (922 TK 111), in the carousel
sequence.
When pulp enters the fourth Pumpcell, Pumpcell No. 4, (922 TK 111), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the fourth Pumpcell, Pumpcell No. 4,
be started.
When the pulp level in the fourth Pumpcell, Pumpcell No. 4, (922 TK 111),
pumped to the fifth Pumpcell, Pumpcell No. 5 (922 TK 110), in the carousel
sequence.
When pulp enters the fifth Pumpcell, Pumpcell No. 5, (922 TK 110), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the fifth Pumpcell, Pumpcell No. 5,
be started.
When the pulp level in the fifth Pumpcell, Pumpcell No. 5, (922 TK 110),
pumped to the sixth Pumpcell, Pumpcell No. 6 (922 TK 109), in the carousel
sequence.
When pulp enters the sixth Pumpcell, Pumpcell No. 6, (922 TK 109), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the sixth Pumpcell, Pumpcell No. 6,
be started.
When the pulp level in the sixth Pumpcell, Pumpcell No. 6, (922 TK 109),
pumped to the seventh Pumpcell, Pumpcell No. 7 (922 TK 108), in the
carousel sequence.
When pulp enters the seventh Pumpcell, Pumpcell No. 7, (922 TK 108), in the
Pumpcell.

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When the hydrofoil is submerged by pulp in the seventh Pumpcell, Pumpcell No.
must be started.
When the pulp level in the seventh Pumpcell, Pumpcell No. 7, (922 TK 108),
pumped to the tails Pumpcell, Pumpcell No. 8 (922 TK 107), in the carousel
sequence.
When pulp enters the tails Pumpcell, Pumpcell No. 8, (922 TK 107), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the tails Pumpcell, Pumpcell No. 8,
be started.
When the pulp level in the tails Pumpcell, Pumpcell No. 8, (922 TK 107),
pumped via the automated residue plug valve (922 300 KXHP 802), to the
residue manifold.
The Pumpcell plant is now considered on line. The predetermined and regular
sampling campaign can now commence.
Periodic inspection for traces of carbon on the residue screen will be required to
determine if carbon is leaking through the interstage screens.
Periodic carbon inventory sampling is required to determine if a Pumpcell is
leaking carbon to the succeeding Pumpcell.
2.3.2 Lead Pumpcell Isolation

The lead Pumpcell is isolated after either a predetermined time period or when
the gold on carbon loading within that Pumpcell, (Pumpcell No. 1,
(922 TK 114), has achieved a level suitable for transferring the loaded carbon
to the elution circuit.
Open the automated feed launder plug valve feeding the second Pumpcell,
Pumpcell No. 2 (922 TK 113), in the carousel sequence. The automated feed
launder plug valve that must open is (922 250 KXHP 005).
Open the two automated feed launder gate isolation valves allowing pulp to
gravitate to the second Pumpcell, Pumpcell 2, (922 TK 113) in the carousel
sequence. The two automated feed launder gate isolation valves that must be
opened are (922 400 KXHG 002) and (922 400 KXHG 004).
Close the automated feed launder plug valve feeding the original head Pumpcell,
Pumpcell No. 1, (922 TK 114), in the carousel sequence. The automated feed
launder plug valve that must close is (922 250 KXHP 001).
Close the automated feed plug valve on the new head Pumpcell, Pumpcell No. 2,
(922 TK 113). The automated feed plug valve to be closed is
(922- 300 KXHP 201).
Close the automated interconnecting tank gate valve between the original head
Pumpcell No. 1, (922 TK 114), and second Pumpcell, Pumpcell No. 2,
(922 TK 113), in the carousel sequence. The automated interconnecting tank
gate valve that must close is (922 450 KXHG 103).
The original head Pumpcell, Pumpcell No. 1, (922 TK 114), in the carousel
sequence is isolated.
The Pumpcell Mechanism, (922 SC 114), drive motor must not be stopped,
the pulp and carbon must be suspended to allow for the efficient drainage of the
isolated Pumpcell.
The second Pumpcell, Pumpcell No. 2, (922 TK 113), in the carousel
sequence the new head Pumpcell.

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The Pumpcell plant is effectively operating with seven Pumpcells on line. It is
therefore imperative that the following two Operating Procedures, Head Pumpcell
Drainage and Tail Pumpcell Sequencing be performed expediently thus ensuring
that all eight Pumpcells are brought on line to ensure that metallurgical
efficiencies are maximised.

2.3.3 Pumpcell Drainage

Prior to draining the original head Pumpcell, Pumpcell No. 1, (922 TK 114),
ensure that the loaded carbon screen is ready to receive pulp and that there is
sufficient capacity in the loaded carbon hopper to receive a batch of loaded
carbon.
Start the loaded carbon screen.
Start the loaded carbon drain pump.
Open the automated loaded carbon diaphragm drain valve on the original head
Pumpcell, Pumpcell No. 1, (922 TK 114). The automated loaded carbon
diaphragm drain valve that must be opened is (922- 150 HD 108).
Ensure that there is sufficient wash water on the loaded carbon screen to wash
all entrapped pulp form the loaded carbon.
When the pulp level in the original head Pumpcell, Pumpcell No. 1,
(922 TK 114), approaches the same elevation as the hydrofoil, the Pumpcell
Mechanism, (922 SC 114), drive motor must be stopped.
When the pulp level in the original head Pumpcell, Pumpcell No. 1,
(922 TK 114), approaches the loaded carbon discharge manifold it is
recommended that the Pumpcell be hosed out with water to ensure that all the
loaded carbon exits the Pumpcell and is recovered on the loaded carbon screen.
When the original head Pumpcell, Pumpcell No. 1, (922 TK 114), is empty the
washing is terminated.
Close the automated loaded carbon diaphragm drain valve on the original head
Pumpcell, Pumpcell No. 1, (922 TK 114). The automated loaded carbon
diaphragm drain valve that must be closed is (922- 150 HD 108).
Stop the loaded carbon pump.
Stop the loaded carbon screen.
The original head Pumpcell, Pumpcell No. 1, (922 TK 114), is ready to be
brought back on line as the new tail Pumpcell.

2.3.4 Tail Pumpcell Sequencing

Ensure that the predetermined amount of carbon is available to be added to the
new tail Pumpcell, Pumpcell No. 1, (922 TK 114), once pulp is introduced into
this Pumpcell.
Open the automated feed plug valve on the new tail Pumpcell, Pumpcell No. 1,
(922 TK 114). The automated feed plug valve to be opened is
(922- 300 KXHP 101).
Open the manual Pumpcell Mechanism discharge gate valve on the new tail
Pumpcell, Pumpcell No. 1, (922 TK 114). The manual Pumpcell Mechanism
discharge gate valve to be opened is (922 450 KXHG 106).
Open the automated residue plug valve on the new tail Pumpcell, Pumpcell No.
1, (922 TK 114). The automated residue plug valve to be opened is
(922 300 KXHP 102).
Close the manual bypass gate valves on the new tail Pumpcell, Pumpcell No. 1,
(922 TK 114). The manual bypass gate valves to be closed are

Page11

(922 400 KXHG 104) and (922 400 KXHG 105).
Close the automated interconnecting tank gate valve on the new tail Pumpcell,
Pumpcell No. 1, (922 TK 114), in the carousel sequence. The automated
interconnecting tank gate valve to be closed is (922 450 KXHG 103).
Open the automated interconnecting tank gate valve between the original tail
Pumpcell, Pumpcell No. 8, (922 TK 107), and the original head Pumpcell,
Pumpcell No. 1, (922 TK 114). The automated interconnecting tank gate
valve to be opened is (922 450 KXHG 803).
Close the automated residue plug valve on the original tail Pumpcell, Pumpcell 8,
(922 TK 107), in the carousel sequence. The automated residue plug valve to
be closed is (922 300 KXHP 802).
Pulp will now be pumped from the original tail Pumpcell, Pumpcell No. 8,
(922 TK 107), to the new tail Pumpcell, Pumpcell No. 1, (922 TK 114).
When pulp enters the new tail Pumpcell, Pumpcell No. 1, (922 TK 114), in the
Pumpcell.
When the hydrofoil is submerged by pulp in the new tail Pumpcell, Pumpcell No.
must be started.
When the pulp level in the new tail Pumpcell, Pumpcell No. 1, (922 TK 114),
pumped via the automated residue plug valve (922 300 KXHP 102), to the
residue manifold.
The Pumpcell plant is back on line.
Regular sampling and observations can commence.

2.3.5 Pumpcell Bypassing

A Pumpcell is bypassed if it is expected that the Pumpcell in question has a
damaged wedge wire screen and is leaking carbon into the next Pumpcell or if the
drive mechanism has failed. The Pumpcell Plant design allows for the changing of a
complete Pumpcell mechanism without having to interrupt the feed to the plant. The
Pumpcell in question is bypassed and the mechanism is removed and replaced by a
mechanism that is maintained in good working order and is located in the
maintenance bay (922 MB 001) provided.

For the purpose of this example Pumpcell No. 1, (922 TK 114), will be the head
Pumpcell and Pumpcell 8, (922 TK 107), will be the tail Pumpcell. Pumpcell No.
2, (922 TK 113), will be the Pumpcell that has a damaged wedge wire screen or
drive mechanism and therefore requires replacement.

Open the manual bypass gate valves on the Pumpcell No. 2, (922 TK 113).
The manual bypass gate valves that must be opened are
(922 400 KXHG 204) and (922 400 KXHG 205).
Close the automated feed plug valve on Pumpcell No. 2, (922 TK 113).The
automated feed plug valve that must be closed is (922 300 KXHP 201).
Stop the Pumpcell Mechanism, (922 SC 113), drive motor.
Close the manual Pumpcell Mechanism discharge gate valve on Pumpcell No. 2,
(922 TK 113). The manual Pumpcell Mechanism discharge gate valve that
must be closed is (922 450 KXHG 206).
Pumpcell No. 2, (922 TK 113), is effectively being bypasses. Pulp exiting the
head Pumpcell, Pumpcell No. 1, (922 TK 114), bypasses Pumpcell No. 2,
(922 TK 113), and is fed into Pumpcell No. 3, (922 TK 112).

Page12

The malfunctioning Pumpcell Mechanism, (922 SC 113), is lifted out of
Pumpcell No. 2, (922 TK 113), by means of the crane.
The malfunctioning Pumpcell Mechanism, (922 SC 113), is placed in the
Maintenance Bay, (922 MB 001).
The spare Pumpcell Mechanism, (922 SC 106), is hoisted from the
Maintenance Bay, (922 MB 001), and placed into Pumpcell No. 2,
(922 TK 113), by means of the crane.
With the spare Pumpcell Mechanism, (922 SC 106), correctly inserted into
Pumpcell No. 2, (922 TK 113), this Pumpcell is brought back on line.
Open the manual Pumpcell Mechanism discharge gate valve on Pumpcell No. 2,
(922 TK 113). The manual Pumpcell Mechanism discharge gate valve that
must be opened is (922 450 KXHG 206).
Start the spare Pumpcell Mechanism, (922 SC 106), drive motor.
Open the automated feed plug valve on Pumpcell No. 2, (922 TK 113). The
automated feed plug valve that must be opened is (922 300 KXHP 201).
Close the manual bypass gate valves on the Pumpcell No. 2, (922 TK 113).
The manual bypass gate valves that must be closed are
(922 400 KXHG 204) and (922 400 KXHG 205).
Pumpcell No. 2, (922 TK 113), is back on line.
It is important to repair the damage to the malfunctioning Pumpcell Mechanism,
(922 SC 113). A mechanism that is in working order must always be available
in the Maintenance Bay, (922 MB 001), thus preventing any prolonged
Pumpcell bypassing from occurring in the event of unforeseen Pumpcell
Mechanism malfunctions or routine maintenance.
2.3.6 Regenerated Carbon Return

The Pumpcell circuit is equipped with an automated Regenerated Carbon Return
manifold. This manifold is used to direct virgin or regenerated carbon from the elution
circuit to a new tail Pumpcell.

For the purpose of this example, Pumpcell No. 1, (922 TK 114), will be the new
tail Pumpcell requiring regenerated carbon from the elution circuit while in the
process of being brought back on line.

This sequence can only be performed in parallel with sequence 5.4 Tail
Pumpcell Sequencing.
Open the automated regenerated carbon return diaphragm valve feeding the
new tail Pumpcell, Pumpcell No. 1, (922 TK 113). The automated
regenerated carbon return diaphragm valve is (922 75 HD 016).
Close the remaining automated regenerated carbon return diaphragm valves
feeding the remainder of the Pumpcell circuit. The automated regenerated
carbon return diaphragm valves that are to be closed are (922 75 HD 017),
(922 75 HD 018), (922 75 HD 019), (922 75 HD 020), (922 75
HD 021), (922 75 HD 022), (922 75 HD 023), (922 75 HD
024), (922 75 HD 025), (922 75 HD 026) and (922 75 HD 027).
Open the regenerated carbon isolation valve feeding Pumpcells 1 4,
(922 TK 114) to (922 TK 111), valve (by others).
Close the regenerated carbon isolation valve feeding Pumpcells 5 8,
(922 TK 110) to (922 TK 107), valve (by others).
A predetermined volume of regenerated carbon is transferred from the elution
circuit via the regenerated carbon return manifold, through the automated
regenerated carbon return diaphragm valve, (922 75 HD 016), feeding the
new tail Pumpcell, Pumpcell No. 1, (922 TK 114).

Page13

Once the regenerated carbon has been transferred to the new tail Pumpcell,
Pumpcell No. 1, (922 TK 114), the regenerated carbon return line must be
flushed.
Once the regenerated carbon return line has been flushed, the automated
regenerated carbon return diaphragm valve feeding the new tail Pumpcell,
Pumpcell No. 1, (922 TK 114), must be closed. The regenerated carbon
return diaphragm valve to be closed is (922 75 HD 016).

2.3.7 Plant Stoppage

When the feed to the Pumpcell circuit is stopped, the pulp level throughout the circuit
equalizes. The equalization involves the back flow of pulp and carbon through a
Pumpcells open feed plug valve, the pulp will flow back through the interconnecting
launder and eventually enter the Pumpcell mechanism. As it is not desirable to get
back flow of pulp and carbon into the superseding Pumpcell mechanism, a procedure
is required to prevent this pulp and carbon back flow.

This procedure involves the closing of all automated feed plug valves and automated
interconnecting launder gate valves. With the before mentioned valves in the closed
position, the back flow of pulp and carbon through the circuit will be eliminated.

The procedure detailing valve sequencing that should be adopted during a plant
stoppage is as follows:

For the purposes of this exercise Pumpcell No.1, (922 TK 114), will be the head
Pumpcell and Pumpcell No. 8, (922 TK 107), will be the tail Pumpcell.

Plant Stoppage

The automated feed plug valve on Pumpcell No. 1, (922 TK 114), will be in
the closed position, valve (922 300 KXHP 101). This valve must remain
closed when the Plant Stoppage procedure is initiated.
The automated feed plug valves on Pumpcells No. 2, (922 TK 113), to
Pumpcell No. 8, (922 TK - 107), must be closed. The automated feed plug
valves to be closed are valves (922 300 KXHP 201),
(922 300 KXHP 301), (922 300 KXHP 401),
(922 300 KXHP 501), (922 300 KXHP 601),
(922 300 KXHP 701) and (922 300 KXHP 801).
The automated interconnecting gate valve between Pumpcell No. 8,
(922 TK 107), and Pumpcell No. 1, (922 TK 114), will be in the closed
position, valve (922 450 KXHG 803). This valve must remain closed when
the Plant Stoppage procedure is initiated.
The automated interconnecting gate valves on Pumpcells No. 1,
(922 TK 114), to Pumpcell No. 7, (922 TK - 108), must be closed. The
automated interconnecting gate valves to be closed are valves
(922 450 KXHG 103), (922 450 KXHG 203),
(922 450 KXHG 303), (922 450 KXHG 403),
(922 450 KXHG 503), (922 450 KXHG 603) and
(922 450 KXHG 703).

The AAC Pumpcell operating philosophy will detail the procedure and valve
sequencing required when performing the tasks.


Page14

3 AAC PUMPCELL DATA SHEET

Table 1 - AAC Pumpcell Data Sheet
MECHANICAL EQUIPMENT DATASHEET
PROJECT INFORMATION
CLIENT MINERA FLORIDA LIMITADA CHILE
PLANT ALHUE DATE MARCH 2011
LOCATION CHILE COMPILED BY G VAN ASWEGEN
DESCRIPTION 135m
3
PUMPCELL PLANT REVISION 0 5
TH
MARCH 2010
QUANTITY 1 X 8 STAGE OPERATIONAL +1 SPARE MECHANISM
DUTY DETAILS MECHANISM DETAILS
NORMAL FLOWRATE m
3
/h per unit 253 MODEL NUMBER AAC MPS 0470(P)
MAXIMUM FLOWRATE m
3
/h per unit 330 NUMBER OF UNITS 9
SLURRY RELATIVE
DENSITY
t/m
3
1.433 SERIAL NUMBERS SM/2025/11-SM/2033/11
SLURRY PERCENTAGE
SOLIDS
% 47 EQUIPMENT NUMBERS
922-SC-114,922-SC-113,
922-SC-112, 922-SC-111,
922-SC-110, 922-SC-109,
922-SC-108, 922-SC-107,
922-SC-106
SLURRY P80 m 75 kW RATING kW 67.875
SLURRY VISCOSITY cP @ 124s
-1
100 MOTOR SIZE kW 30
SLURRY pH pH 10 12 SERVICE FACTOR INSTALLED 2.26
SOLIDS SPECIFIC GRAVITY t/m
3
2.8 ABSORBED POWER kW 23.62
PRE-SCREEN APERTURE m 800 SERVICE FACTOR ABSORBED 2.87
CARBON SIZE mesh 6x16 OUTPUT SPEED RPM 33.75
CARBON CONCENTRATION g/l 25 SCREEN DETAILS
MOTOR DETAILS TYPE WEDGE WIRE
VOLTAGE V(AC) 380 PERCENTAGE OPEN AREA % 26.7
FREQUENCY Hz 50 SCREEN APERTURE m 800
PHASE 3 SCREEN SURFACE AREA m
2
4.67
ENCLOSURE IEC IP66 SCREEN PROFILE 28CP
FRAME IEC SCREEN MATERIAL 304 SS WEDGE WIRE
MOUNTING FLANGE CAGE DETAILS
SPEED 4 POLE NUMBER OF BLADES 5
AMBIENT TEMPERATURE 25 PULSE RATE pulses/sec 2.81
SUPPLIER WEG CAGE TIP SPEED m/min 182
SUPPORT STRUCTURE LOADS MATERIALS OF CONSTRUCTION
TOTAL NETT MASS kg 4980 SCREEN 304 STAINLESS STEEL
OPERATING MASS kg 6445 ROTATING CAGE 300WA NATURAL RUBBER LINED
TOTAL GROSS MASS
2
kg 9655 VOLUTE 300WA NATURAL RUBBER LINED
BENDING MOMENT Nm 5303 CORROSION PROTECTION IMMERSION EPOXY
TORQUE Nm 6310

375 m DFT
AXIAL LOAD kN 106
NOTE:
2
Total gross mass is calculated as total nett mass +80 % of
the cylinder volume containing settled pulp having 80 % dry
solids mass. This is an unlikely operating condition.


Page15

4 SPARE PARTS
4.1 Spare Parts Numbering Designations

For the purposes of clarity during the assembly and the procurement of spare parts, it
is worth understanding the numbering sequence by which the relevant sub-
assemblies and the individual components are identified.

An example of a component number is given below. (Note: The number is an
example only and is not necessarily specific to your contract.) A description of each
segment of the part number follows.

1. This section of the number gives the unique Kemix contract number specific to
your equipment. This number should be quoted when inquiring about any
information from Kemix regarding your equipment. The prefix has the following
meanings:
C indicates a local, South African supply contract.
L indicates an indirect export contract.
E indicates a direct export contract.
2. This section of the number is an internal number used to identify the type of
equipment that has been supplied. 71 is typical for Pumpcell technology.
3. This section indicates a sub-assembly. Each subassembly has a unique number
e.g. 03.
4. This section indicates a specific part number. Each part number within a sub-
assembly has a unique number e.g. 04.

The following diagram indicates all the individual parts and there associated
part numbers related to the Kemix AAC Interstage Screen The description
detail of the parts and ex-works manufacturing lead time can be obtained by
relating the part number to the description on the table that follows the
diagram.

E70444 - 71- 03-04
1 2 3 4

Page16

A
DETAIL A
( 1 : 20)
B
DETAIL B
( 1 : 35)
E70415 - 72-01-03
MOUNTING BASE
E70415 - 51 GEARBOX OPERATIONAL SPARES
E70415 - 52 GEARBOX FILTER BREATHER
E70415 - 40 MOTOR
E70415 - 41 MOTOR TERMINAL BOX
E70415 - 42 MOTOR TERMINAL BOX COVER
E70415 - 43 MOTOR FAN COWL
E70415 - 44 MOTOR FAN
E70415 - 45 MOTOR DRIVE ENDSHIELD
E70415 - 46 MOTOR NON-DRIVE ENDSHIELD
E70415 - 47 MOTOR DRIVE ENDOIL SEAL
E70415 - 48 MOTOR NON-DRIVE ENDOIL SEAL
E70415 - 72-01-04
GEARBOX COUPLING
E70415 - 50 GEARBOX &MOTOR ADAPTER
E70415 - 31
10mROLL COMPRESSIBLE NEOPRENE STRIP GASKET
(INSERTEDBETWEEN WEDGE WIRE SCREEN,
VOLUTE AND HYDRAULIC LEG)
E70415 - 72-06-07
RUBBER LINEDPULSE BLADE
E70415 - 72-05-06
PUMP MOUNTING FLANGE
E70415 - 72-04
PUMP IMPELLOR
E70415 - 72-06
RUBBER LINED ROTATING CAGE
E70415 - 72-04-03
RUBBER LINED PBT
E70415 - 72-03-01
CYLINDRICAL WEDGE WIRE SCREEN
E70415 - 72-02-03
RUBBER LINEDVOLUTE
E70415 - 72-01-03
BASE PLATE
E70415-33
WET-END
FASTENERS REGION
E70415-32
DRY-END
FASTENERS REGION
E70415 - 72-02-04
RUBBER LINEDINTERFACE SEAL
E70415 - 72-05
FIRST SHAFT ASSEMBLY
E70415 - 72-03-02
HYDRAULIC LEG
E70415 - 72-07
SECONDAGITATOR SHAFT
E70415 - 72-07-03
HYDROFOIL BLADE WITH STABILISER
E70415 - 72-03-00-01
DRAIN SOCKET
E70415 - 72-03-00-01
DRAIN PLUG
E70415 - 72-01-05
NAME PLATE BRACKET


Page17

Table 2 - AAC MPSP Interstage Screen Complete Parts List
INTERSTAGE SCREENS: COMPLETE SPARE PARTS LIST

REFERENCE DRAWING: E70444-72
PART DESCRIPTION KEMIX PART NUMBER EX WORKS LEAD
TIME
Base plate E70444 -72-01-03 8 Weeks
Rubber lined volute & top structure assembly E70444 -72-02-03 12 Weeks
Rubber lined volute interface seal E70444 -72-02-04 4 Weeks
Rubber lined pumping impeller E70444 -72-04 12 Weeks
Rubber lined PBT (set) E70444 -72-04-03 6 Weeks
First shaft assembly E70444 -72-05 10 Weeks
Pump coupling E70444 -72-05-06 4 Weeks
Hydraulic leg E70444 -72-03-02 8 Weeks
Cylindrical wedge wire screen E70444 -72-03-01 8 Weeks
Rubber lined rotating cage E70444 -72-06 10 Weeks
Rubber lined pulse blades (set) E70444 -72-06-07 4 Weeks
Second agitator shaft E70444 -72-07 10 Weeks
Hydrofoil blade with stabiliser E70444 -72-07-03 8 Weeks
Hook mounting support set (2 per set) E70444 -26 8 Weeks
Hold down clamp set (2 per set) E70444 -22 8 Weeks
Dry end fasteners E70444 -32 4 Weeks
Wet end fasteners E70444 -33 4 Weeks
Motor E70444 -40 16 Weeks
Motor terminal box E70444 -41 16 Weeks
Motor terminal box cover E70444 -42 16 Weeks
Motor fan cowl E70444 -43 16 Weeks
Motor fan E70444 -44 16 Weeks
Motor drive end shield E70444 -45 16 Weeks
Motor non-drive end shield E70444 -46 16 Weeks
Motor drive end oil seal E70444 -47 16 Weeks
Motor non-drive end oil seal E70444 -48 16 Weeks
Gearbox & motor adaptor E70444 -50 16 Weeks
Gearbox operational spares set E70444 -51 10 Weeks
Gearbox filter breather (6 month shelf life) E70444 -52 4 Weeks
Gearbox coupling E70444 -72-01-04 8 Weeks
10m roll compressible neoprene strip gasket E70444 -31 4 Weeks
Hydraulic leg drain plug and socket set E70444 -72-03-00-01 4 Weeks


Page18

5 UNPACKING AND ASSEMBLY PROCEDURE AFTER
TRANSPORTATION.

For shipping purposes the Kemix AAC Interstage Screen is equipped with various
locking and support brackets to safe guard the Interstage Screen from damage
during transit. The locking brackets are used to enable the rotating parts of the
Interstage Screen to be locked in place forming one ridged assembly whereas the
support brackets are used to support the Interstage Screen in the horizontal transport
position. These locking and support brackets are to be removed before the
Interstage Screen is placed into operation or before the Interstage screen is
rotated. The location of the brackets and the procedure steps for removing the
brackets are as follows:

NOTE: THE BELOW PROCEDURE ORDER MUST BE FOLLOWED (i.e. START
WITH STEP 1, THEN STEP 2, THEN STEP 3, THEN STEP 4 AND FINALLY STEP
5).
5.1 Step 1 - Removal of the Rotating Cage Support A-Frame

Before any of the locking and support brackets are removed, the Kemix Interstage
Screen needs to be placed inside the maintenance bay in a vertical position (refer
section 7) using the provided four lifting lugs located inside the volute top structure
(refer to figure 3).

The first support bracket required to be removed is the rotating cage support A-frame
(refer to figure 5) located at the bottom end of the Interstage Screen. The procedure
for removal is as follows:

1. Whilst the Interstage Screen is in a vertical position situated inside the
maintenance structure, nylon slings and chain blocks must be used to secure
the rotating cage to the maintenance bay structure (refer to figure 4).
2. The fasteners connecting the A-frame arms to the bottom flange of the wedge
wire screen need to be unbolted and removed (refer to figure 5).
3. Next the fasteners connecting the A-frame bracket to the rotating cage hub
and shaft flange must be unbolted and removed. As per point 1 above, the
rotating cage assembly is supported by nylon slings attached to the
maintenance bay structure steelwork and there is therefore no risk of the
rotating cage dropping due to removal of support brackets.
4. Once the A-frame has been detached from the Interstage Screen assembly
and removed, the centre bolt located in the center of the rotating cage hub
needs to be removed. The fasteners that were unbolted to remove the A-
frame as well as the centre bolt located in the center of the rotating cage hub
must not be re-inserted until completion of step 3.


Figure 3 Provided Lifting Lugs for Hoisting the Interstage Screen Vertically

Figure 4 Supporting the Rotating Cage using Nylon Slings and Chain Blocks

VOLUTE
LIFITING LUG
NYLON
SLINGS
CHAIN
BLOCK

Figure 5 Location of Rotating Cage Support A-Frame

Figure 6 Center Bolt Located in Center of Rotating Cage Hub

A-FRAME
ARM
ROTATING
CAGE HUB
FASTENERS
A-FRAME
BOTTOM
FLANGE
OF
WEDGE
WIRE
SCREEN
5.2 Step 2 - Removal of the front 1st shaft Locking Brackets

This next step is to be completed after step 1 has been completed. The locking
bracket located on top of the volute internal frame (refer figure 7) needs to be
removed. The procedure for removal is as follows:

1. Unbolt and remove all the fastener nuts and threaded bars located between
the top shaft flange and the channels which are bolted on the top of the volute
internal frame. The shaft and pump assembly is supported by brackets
located between the volute moat and pump assembly (see section 5.3) and
there is therefore no risk of the shaft and pump assembly dropping due to no
support.
2. Unbolt the channels from the top of the volute internal frame and remove.

Figure 7 Location of the front 1
st
shaft Locking Brackets

CHANNEL
BRACKETS
ON VOLUTE
INTERNAL
FRAME
THREADED
BAR
FASTENER
NUTS

Page22

5.3 Step 3 - Removal of the Pump Support Brackets.

This step is to be completed once step 2 has been completed. The pump assembly
support brackets are located on the inside of the Interstage Screen volute as shown
in figure 8. The procedure for removing the brackets is as follows:

1. Using the maintenance crane, lift the shaft and pump assembly using the
pump lifting lugs on the top of the pump to a height that allows the easy
removal of the four pump support brackets from the volute moat (refer figure
8). Care should be taken when lifting the pump assembly not to damage the
pump flange on the internal structure of the volute.
2. Inspect the circumference of the volute moat to ensure that all four of the
pump support brackets have been identified and removed.
3. Using the maintenance crane still hoisting the shaft and pump assembly using
the pump lifting lugs on the top of the pump, slowly (creep/inch function) lower
the shaft and pump assembly until the bottom flange of the shaft comes in
contact with the hub of the rotating cage. Special pre-cautions must be
taken to ensure that the shaft and pump assembly is only lowered until
the bottom flange of the shaft creates a gap of approximately 5mm from
rotating cage hub. Lowering of the shaft and pump assembly to low
might result in damage to the rotating cage.
4. The centre bolt located in the center of the rotating cage hub can now be
inserted and the 5mm gap can be taken up by tightening the rotating cage
hub center bolt (refer to figure 9). This will secure the rotating cage and shaft
together. Ensure the bolts of the shaft flange and rotating cage hub are
inserted before tightening of the center bolt of the rotating cage to ensure all
the flange bolt holes for the rotating cage and shaft are aligned. Special
attention must be given to ensure that shaft flange and rotating cage is
correctly coupled together (refer section 6.9).

Note: The weight of the shaft and pump assembly must remain supported by
the maintenance crane until completion of step 4.


Figure 8 Location of Pump Support Bracket

Figures 9 Assemble the 1
st
shaft to the Rotating Cage with 5mm Gap
PUMP
SUPPORT
BRACKET
VOLUTE
MOAT
PUMP
LIFTING
LUGS
5mm GAP
5.4 Step 4 - Removal of the Rotating Cage Locking Brackets

After completion of step 3, with the shaft and pump assembly still being hoisted by
the maintenance crane, the rotating cage locking brackets must now be removed.
The rotating cage locking brackets are located between the top of the rotating cage
and the top flange of the screen (refer to figure 10). The procedure is as follows:

1. The clamping fasteners on the rotating cage locking brackets need to be
unbolted (refer to figure 11).
2. The fasteners connecting the rotating cage locking brackets to the top flange
of the wedge wire screen must then be unbolted (refer to figure 11).
3. The rotating cage locking brackets can now be removed and the fasteners
removed from the top flange of the wedge wire screen must be reinserted and
tightened (refer to section 12).
4. The shaft and pump assembly still being hoisted by the maintenance crane
can now be slowly (creep/inch function) lowered until the pump assembly
comes to rest on the volute moat.

Figure 10 Location of Rotating Cage Locking Brackets

ROTATING
CAGE
LOCKING
BRACKET

Figure 11 Location of Rotating Cage Support Locking Bracket

CLAMPING
FASTENER
SCREEN TOP
FLANGE
FASTENER

Page26

5.5 Step 5 Assembly of the Kemix Interstage Screen from the
Transported State of Partial Assembly

This step involves the full assembly of the Kemix Interstage Screen for operation
from the partial state of assembly in which the Interstage Screen was transported.
The assembly activities required are as follows:

1. Install the gearbox and baseplate assembly as per section 6.6 and section
6.7. Ensure the oil, breathers and sight glass is installed.
2. The agitator blades and agitator shaft can now be assembled as per section
6.1.7.
3. After the agitator blades and shaft have been assembled, the agitator blades
and shaft assembly must be bolted onto the underside of the rotating cage
hub as per section 6.10.

NOTE: Before the Interstage Screens are placed into operation, the inspections
identified in Section 7.1 of this manual must be performed.


Page27

6 COMPLETE BREAKDOWN OF MECHANISM FOR
ASSEMBLY

The complete assembly of the mechanism from a completely dismantled state is
detailed below. A list of tools required is given in section 13. All bolts should be
torqued to the values specified in section 12.

The next eight sections (sections 6.1.1 to 6.1.8) refer to pre-assembly activities that
are required before the main assembly is assembled. The sections 6.2 to 6.10 refer
to the main assembly of the Interstage Screen.

6.1 Pre-Assembly requirements 1 to 8
6.1.1 Pre-Assemble 1: the Pulse Blades to the Rotating Cage

The parts required for this procedure are:

Pulse Blades E70444-72-06-07
Rotating Cage E70444-72-06

The recommended assembly procedure is as follows:

1. The rotating cage has a leading drilling pattern as seen in figure 13. The pulse
blade holes are not centered on the upright of the rotating cage and therefore the
blades should be mounted in a specific orientation.
2. Assemble the pulse blades, with the provided stainless steel nuts, bolts and
oversize washers, so that the inner edge of the pulse blade overlaps the upright
angle of the rotating cage by +/- 10mm as shown in Figure 13.

The pulse blades are sacrificial items. Their purpose is to protect the rotating cage
uprights from wear during operation. Incorrect orientation of the pulse blades will
result in premature wear of the rotating cage uprights a much more costly
replacement than a set of pulse blades.


Page28

Figure 12 - Assembly of Pulse Blades

Figure 13- Orientation of Pulse Blades

DIRECTION OF
ROTATION
PLAN VIEW
PULSE BLADE
ROTATING
CAGE
PULSE
BLADE

Page29

6.1.2 Pre-Assemble 2: the Hydraulic Leg to Screen


Hydraulic Leg E70444-72-03-02
Hydraulic leg drainage plug and socket set E70444-72-03-00-01
Wedge Wire Screen E70444-72-03-01


1. Apply the 50mm wide neoprene strip to one side of the flange of the drainage
socket.
2. Using a fairly sharp object to push holes through the neoprene rubber strip to
coincide with the holes located on the flange of the drainage socket.
3. Assemble the hydraulic leg drainage port to the hydraulic leg using the provided
stainless steel fasteners as shown in Figure 14.
4. Affix 50mm width neoprene rubber to the flange on the underside of the hydraulic
leg disc. (This serves as a sealing gasket between the hydraulic leg and the
wedge wire screen.)
5. Use a fairly sharp object to push holes through the neoprene rubber strip
coinciding with the holes in the hydraulic leg.
6. Lower the hydraulic leg into the wedge wire screen.
7. Bolt the hydraulic leg to the screen using the given stainless steel fasteners as
shown in Figure 15.
8. Check that the hydraulic leg pipe is concentric to the wedge wire screen at the
top flange.
9. If the hydraulic leg is not concentric to the screen, excessive wear will
occur against the main shaft or pump assembly during operation.


Page30

Figure 14 Assembling the Hydraulic Leg Drainage Port

Figure 15 - Assembling the Hydraulic Leg to the Screen
6.1.3 Pre-Assemble 3: the Female Rigid Coupling to the Gearbox Output
Shaft

Gearbox (c/w key) E70444-50
Female Rigid Coupling (c/w keep plate) E70444-72-01-04

The recommended assembly procedure, using Figure 16 as a reference, is as
follows:

1. Insert the gearbox key into the gearbox output shaft.
2. Slide the female half of the rigid coupling over the output shaft and key.
3. Bolt the female rigid coupling keep plate into the recess in the coupling using the
provided fasteners. Using the torque table in section 12, ensure the fasteners are
correctly tightened.
4. Ensure the oil, breathers and sight glass is installed (refer section 18).

Figure 16 Assembling the female half of the rigid coupling to the gearbox

NAMEPLATE
BRACKET
ELECTRIC
MOTOR
GEARBOX
GEARBOX KEY
FEMALE RIGID
COUPLING
FEMALE RIGID
COUPLING
KEEP PLATE


Page32

6.1.4 Pre-Assemble 4: the Gearbox to Base Plate


Gearbox (c/w key) E70444-50
Gearbox Baseplate E70444-72-01-03

The recommended assembly procedure, using Figure 17 and 18 as a reference, is as
follows:

1. Place gearbox base plate on chocks as indicated in figure 17.
2. Place the Gearbox assembly onto the baseplate, making sure the holes on the
underside of the gearbox locates correctly with the baseplate holes. Precautions
should be taken to ensure that the lubricating pipe work on the gearbox is not
damaged when placing the gearbox onto the base plate.
3. Using the provided fasteners, bolt the gearbox to the base plate. Using the torque
table in section 12, ensure the fasteners are correctly tightened.

Note: Once the gearbox and baseplate assembly is complete, ensure that the
assembly is correctly supported. This is done by using the appropriate
chocking to support two ends of the baseplate as seen in figure 19. This is to
ensure a clearance is obtained between the gearbox output shaft and the
ground and that the gearbox and baseplate are secured in a stable position.

Figure 17 Positioning of the Gearbox onto the Baseplate


Page33

Figure 18 Assembly of the Gearbox to Baseplate

Figure 19 Correct supporting of the gearbox and baseplate assembly


Page34

6.1.5 Pre-Assembly 5: Assemble the pump


Pump Inner Cone E70444-72-04
Pump Outer Cone E70444-72-04
PBT Blades E70444-72-04-03


1. Using the appropriate lifting equipment (nylon slings, chain blocks and overhead
cranes), stand the pump inner cone upside down on the flange face. The pump
inner cone may be manipulated using the lifting lugs on the top disc, as shown in
Figure 21.
2. Lower the pump outer cone over the inner cone whilst being careful not to
damage any of the rubber lining.
3. Locate the bolting tabs of the outer cone through the matching slots of the inner
cone, as shown in Figure 21, whilst being careful not to damage the tabs when
aligning the parts.
4. Bolt up the two cones using the appropriate stainless steel bolts. Using the torque
table in section 12, ensure the fasteners are correctly tightened.
5. Turn the pump over so that the flange is now at the top and stand it on the pipe
shaft whilst keeping it steady using the lifting equipment. Make sure that the
protective coating is protected from damage at all times.
6. Attach the PBT to the bottom of the pump using the stainless bolts as shown in
Figure 22. Using the torque table in section 12, ensure the fasteners are correctly
tightened.

Figure 20 Exploded Pump Assembly


Page35

Figure 21 - Pump bolting tabs and lifting lugs

Figure 22 - Bolting the PBT blades to the pump

PUMP
INNER
CONE
TABS
PUMP
OUTER
CONE
TABS
LIFTING
LUGS

Page36

6.1.6 Pre-Assembly 6 Assemble the pump coupling to the first shaft


First Shaft E70444-72-05
Pump Coupling E70444-72-05-06


1. Using eye-bolts in the two provided tapped holes on the pump coupling, position
the two halves of the pump coupling to facilitate the attaching of the pump
coupling halves onto the mid-flange of the shaft as shown in figure 23.
2. Using the supplied fasteners, bolt the pump coupling onto the shaft mid-flange.
Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figure 23 - Bolting the pump coupling halves onto the shaft


Page37

6.1.7 Pre-Assemble 7: Agitator Blades to agitator shaft


Agitator shaft E70444-72-07
Agitator blades E70444-72-07-03


1. With the agitator shaft being held vertically, the agitator blades must be
assembled to the agitator shaft using the provided fasteners.
2. The blades have an area free of rubber lining which must be mated with the
underside of the corresponding spoke on the agitator shaft as shown in Figure
24. Using the torque table in section 12, ensure the fasteners are correctly
tightened.

Figure 24 - Fitting the agitator blade to the agitator shaft

SPOKE
BLADE
AGITATOR
SHAFT

Page38

6.1.8 Pre-Assemble 8: Volute Interface Seal to Volute


Volute Assembly (excluding internal frame) E70444-72-02-03
Volute Interface seal E70444-72-02-04


1. With the volute being placed vertically up, the volute interface seal must be
assembled to the volute using the provided fasteners (refer figure 25).
2. Once assembled ensure that the volute interface seal is completely flat against
the volute opening face with no gaps evident. Using the torque table in section
12, ensure the fasteners are correctly tightened.

Figure 25 - Fitting the Volute Interface Seal to the Volute


Page39

6.2 Position the Volute into the maintenance structure


Volute Assembly (excluding internal frame) E70444-72-02-03


1. Lift the Volute Assembly (excluding internal frame) using slings and shackles
through the four provided lifting lugs inside the volute top structure.
2. Lower the volute into to mounting facility located on the top level of the
maintenance bay, making sure that the rubber lining on the volute does not get
damaged during the process.

Figure 26 Positioning of Volute into Maintenance Bay


Page40

6.3 Position the Pumping Impeller into the Volute


Assembled pump as given in section 6.1.5 E70444-72-04
Mechanism as assembled in section 6.2


1. Lift the pump assembly using slings and shackles on the provided lifting lugs.
2. Lower the pump into the volute, making sure that the pump PBT blades do not
get damaged during the process. The pump will come to rest on the volute moat.

Figure 27 Positioning of Pumping Impeller into the Volute


Page41

Figure 28 Positioning of Pumping Impeller into the Volute


Page42

6.4 Assemble the 1
st
Shaft into Pumping Impeller


1
st
Shaft and pump coupling assembly (see section 6.1.6)


1. With the use of nylon slings, attach slings around underside of 1st shaft top
flange lift the shaft into position as shown in Figures 29 & 30.
2. Once the shaft is in position, bolt both the pump flange and the pump coupling
(already coupled to the 1
st
shaft flange, see section 6.1.6) together with the
supplied fasteners. Using the torque table in section 12, ensure the fasteners are

Figures 29 Positioning of 1st Shaft into Pumping Impeller


Page43



Page44

6.5 Position the Internal Frame Into the Volute


Internal frame


1. Lift the internal frame using slings into the volute.
2. Assemble the internal frame onto the volute using the given mild steel fasteners.

Note: The internal frame can only be inserted in one orientation. Make sure that the
frame is orientated such that the shaft is central to the square opening in the internal
frame.

Figures 31 Positioning of the Internal Frame into the Volute


Page45

Figures 32 Positioning of the Internal Frame into the Volute


Page46

6.6 Assemble the Gearbox and Base Plate Assembly onto the Internal
Frame


Gearbox (gearbox, motor and coupling) and baseplate assembly as per section
6.1.4.
Mechanism as assembled as per section 6.5.


1. Place the gearbox and baseplate assembly onto the volute internal frame, making
sure the holes on the underside of the baseplate locates correctly with the volute
internal frame holes and that the motor end of the gearbox is facing the volute
opening side of the volute.
2. Bolt the gearbox and baseplate assembly to the volute internal frame using the
provided fasteners. Using the torque table in section 12, ensure the fasteners are

Figures 33 Assemble the Drive Unit onto the Base Plate


Page47

Figures 34 Assemble the Drive Unit onto the Base Plate


Page48

6.7 Assemble the Gearbox coupling onto the 1
st
Shaft




1. Using the maintenance crane, slowly (creep/inch function) lift the shaft and pump
assembly using the lifting lugs on the top of the pump to a height that allows the
bolting of the gearbox coupling and 1
st
shaft flange to be coupled together as
shown in figure 35 and 36.
2. Bolt the gearbox coupling to the 1
st
shaft top flange using the provided fasteners.

NOTE: Special attention must be given to ensure that the gearbox coupling and
1
st
shaft flange are correctly coupled together, for example the two flange faces
are in full contact.

Figures 35 Positioning of the 1st Shaft up to the Gearbox Coupling


Page49

Figures 36 Coupling the 1st Shaft to the Gearbox Coupling


Page50

6.8 Assemble the Hydraulic Leg and Screen Assembly to the Volute


Hydraulic leg and Screen assembly per section 6.1.2


1. Apply a 50mm wide neoprene rubber to the top flange of the wedge wire screen
as shown in Figure 39.
2. Use a fairly sharp object to push holes through the neoprene rubber strip
coinciding with the holes in the screen flange.
3. Hoist the Hydraulic leg and Screen assembly up to the under side of the volute.
4. Bolt the screen top flange to the volute using the given stainless steel nuts, bolts
and washers. Using the torque table in section 12, ensure the fasteners are




Figure 39 Apply Neoprene rubber to screen top flange and assemble to volute
flange.

NEOPRENE
RUBBER
TO GO ON
SCREEN
TOP
FLANGE

Page52

6.9 Assemble the Rotating Cage to the 1
st
Shaft


Rotating cage assembly as per section 6.1.1.


1. Stand the rotating cage upright on a flat surface that will not inflict damage to the
rubber lining.
2. Bring the rotating cage up to meet the bottom flange of the 1
st
shaft. Attach the
rotating cage using only the center bolt/stud and washer supplied (refer figure
41).

st
shaft to the Rotating Cage


Page53

st
shaft to the Rotating Cage


Page54

6.10 Assemble Agitator to the Mechanism


Agitator shaft and blade assembly as per section 6.1.7
Mechanism as assembled to section 6.9


1. The agitator assembly should be positioned under the mechanism for assembly.
2. The agitator shaft flange, the rotating cage and the main shaft flange must then
be bolted together using the required washers, nuts and bolts as shown in Figure
42. The centre bolt holding the rotating cage onto the 1
st
shaft must remain
in position. Using the torque table in section 12, ensure the fasteners are

Note: At this stage, the assembly of the mechanism is complete. Before the
Interstage Screen is placed into operation, the inspections identified in Section
7.1 of this manual must be performed.

Figure 42 - Assembling the agitator onto the mechanism

AGITATOR
SHAFT

Page55

7 CHECKING AND ADJUSTMENT OF THE MPSP
INTERSTAGE SCREEN BEFORE OPERATION

Note: It is necessary to have a maintenance bay, as shown in Figure 43, in order to
perform the following checks and adjustments. The Mechanism should be vertical
and the rotating cage free to rotate. It is assumed from hereon that the Mechanism is
located in such a structure.

A typical Kemix maintenance bay is shown in Figure 43. It has three or four levels in
order to access the mechanism to adjust and clean all the required parts. The upper
level allows access to the drive section and adjustment of the pump heights etc. The
middle levels allows for high pressure washing of the wedge wire screen during
cleaning and also inspection of the rotating cage. The lower level allows the screen
and rotating cage to be lowered onto a trolley in order to facilitate assembly and
disassembly. The trolley allows the components to be moved to a position that can
be reached by an overhead crane. It also has an extra docking bay in order to
facilitate speedy replacement of the mechanisms in the circuit.

Figure 43 - Kemix maintenance bay

HOOKS
CLEANING
PLATFORM
SCREEN
REMOVAL
PLATFORM
EXTRA BAY FOR
REPLACEMENT
MACHINE

Page56

7.1 Perform Alignment Checks on Shaft and Rotating Cage

When the mechanism is operating, there are two problems that may occur with
respect to alignment of the shaft and rotating cage.

The shaft may rotate off center.
The shaft may not hang perfectly vertical.
The rotating cage does not rotate with a uniform distance around the wedge wire
screen.

To check whether either of the above is occurring, turn the mechanism manual (with
out switching on the power) whilst the mechanism is located within the maintenance
structure. While the mechanism is being manually rotated the following checks must
be performed:

1. The clearance between the rotating cage and wedge wire screen must be
uniform around the circumference and the length of the wedge wire screen
(refer to figure 50). If the clearance between the rotating cage and wedge wire
screen is not uniform, the most likely causes are as follows:
i. The shaft has bent during transportation or handling. For minor bends
in the shaft, the shaft can usually be straightened but if the shaft is
severely distorted, a replacement shaft must be installed into the
mechanism.
ii. The rotating cause has distorted either through transportation or
handling. If the distorting is minor, the rotating cage can usually be
straightened but if the rotating cage is severely distorted, a
replacement rotating cage must be installed onto the mechanism.
iii. The pump coupling or gearbox coupling is not correctly fitted and
properly engaged, refer to point 2 below.

2. The deflection of the shaft at the bottom of the mechanism (where the shaft
couples to the rotating cage) must not be over 10mm. This is most likely
caused due to the incorrect installation of the pump coupling. The shaft will
deflect due to the unbalanced mass of the pumping impeller if the pump
coupling is not correctly seated on the shaft and pump flange. This can be
corrected by re-fitting the pump coupling correctly ensuring the pump coupling
makes complete contact with both the shaft and pump flange. If the gearbox
coupling is not correctly fitted and properly engaged, this will cause the shaft
to deflect.


Page57

8 INSTALLATION AND REMOVAL OF AN AAC PUMPCELL
INTERSTAGE SCREEN

The details of installing an AAC Pumpcell Interstage Screen into a tank of a Pumpcell
plant are detailed in this section.
8.1 Installation
8.1.1 Open Hook Mounting Bracket and Hold Down Clamp

1. Pull out the hook mounting bracket arm retaining pin as shown in Figure 44.
2. Retract the hook mounting bracket arm as shown in Figure 44.
3. Remove the hold down clamp retaining pin as shown in Figure 45.
4. Retract the hold down clamp arm as shown in Figure 45.
8.1.2 Lower And Position The Mechanism In The Tank

1. An overhead crane, with slings attached to the lifting lugs located on the inside of
the volute top structure, is used to manipulate the mechanism.
2. Lower the mechanism into the centre of the port in the tank top structure so that
there is clearance around the entire mechanism.
3. Care should be taken to avoid damage to the agitator, rotating cage and volute
during lowering.
4. The mechanism should be lowered to a height where the mechanism hooks are
slightly above the hook mounting bracket as shown in Figure 46.
5. Move the mechanism towards the launder interface until the launder and
mechanism interfaces are in contact as shown in Figure 47 and 48.
8.1.3 Position And Secure The Mechanism

1. Lower the mechanism onto the hook mounting bracket so that the hooks engage
with the hook pin.
2. Once the load of the entire mechanism has been taken up by the hook mounting
bracket, a visual inspection of the seal between the interface of the volute
opening and the launder should be made in order to establish whether an
adequate seal has been achieved.
3. If there appears to be any visible gap between the interface of the volute opening
and the launder, the hook mounting bracket is adjusted using the procedure
indicated in section 8.1.4.
8.1.4 Adjusting the Hook Mounting bracket

1. Taking the weight of the Pumpcell Interstage screen off of the hook mounting
bracket, by lifting the Interstage Screen slightly up, loosen the bolts fastening the
hook mounting bracket to the top structure of the tank. The hook mounting
bracket can then be moved forward or backward as required using the slotted
holes provided on the hook mounting bracket.
Refer to figure 47 related to a gap being experienced at the bottom of the
volute opening and launder interface.
Refer to figure 48 related to a gap being experienced at the top of the
volute opening and launder interface

Page58

2. Once the desired position has been achieved, the hook mounting bracket can
then be secured by tightening the fastener bolts and the Interstage screen is re-
positioned as per section 8.1.3.
8.1.5 Tighten Hook Mounting Bracket and Hold Down Clamp

1. Return the hook mounting bracket arm in to a position over the hook of the
Interstage Screen.
2. Replace the hook mounting bracket arm retaining pin.
3. Tighten the hook mounting bracket arm screw and locknut.
4. Return the hold down clamp arm in to a position over the top structure of the
Interstage Screen.
5. Replace the hold down clamp arm retaining pin.
6. Tighten the hold down clamp arm screw and locknut.

Figure 44 Hook Mount Locking Bracket


Page59

Figure 45 - Holding down clamp

Figure 46 - Checking the position of the hook pin locking device
HOLDING DOWN
CLAMP ARM
HOLDING DOWN
CLAMP ARM
SCREW
HOLDING DOWN
CLAMP ARM
RETAINING
PIN

Page60

Figure 47 - Correcting a gap at the bottom of interface

Figure 48 - Correcting a gap at the top of interface
SLIDE HOOK MOUNTING BRACKET
IN THIS DIRECTION

GAP AT TOP
GAP AT BOTTOM
SLIDE HOOK MOUNTING BRACKET
IN THIS DIRECTION

Page61

8.2 Removal
8.2.1 Open Hook Mounting Bracket and Hold Down Clamp

1. Loosen the hook mounting bracket arm screw and locknut as shown in 44.
2. Pull out the hook mounting bracket arm retaining pin as shown in 44.
3. Retract the hook mounting bracket arm as shown in 44.
4. Loosen the hold down clamp arm screw and locknut as shown in Figure 45.
5. Remove the hold down clamp retaining pin as shown in Figure 45.
6. Retract the hold down clamp arm as shown in Figure 45.
8.2.2 Lift the Interstage Screen Out Of The Tank

1. An overhead crane, with slings attached to the lifting lugs, is used to manipulate
the mechanism.
2. The seal between the interfaces must be broken by lifting the machine slightly.
Care should be taken not to lift the Interstage Screen too far as this will damage
the volute interface seal.
3. Once the seal has been broken, the Interstage screen must be moved away from
the launder interface to a position where there is approximately the same
clearance on all four sides of the volute top structure.
4. The Interstage screen must then be lifted slowly out of the tank.
5. Care should be taken to avoid damage to the agitator, rotating cage and volute
during lifting.


Page62

9 MAINTENANCE AND INSPECTION PROCEDURE

9.1 Maintenance and Inspection Procedure during normal operation

The followings Maintenance and Inspection procedure activities are related to the
maintenance and inspection requirements during operation of the Kemix Interstage
Screen:

9.1.1 Maintenance and Inspection of the Wedge Wire Screen

The wedge wire screen of each of the Kemix Interstage Screen should be washed
and inspected once every two weeks. If the Kemix Interstage Screen is operated
outside of the process specifications indicated on the Interstage Screen general
arrangement drawing, the time frame between cleaning intervals could be shortened.
The recommended cleaning procedure is as follows:

1. The Kemix Interstage Screen is taken out of operation and placed within a
maintenance structure (refer to section 7).
2. The inspection ports located on the bottom of the hydraulic leg are then
opened (using the provided drainage port wrench, see Figure 49) to facilitate
the washing out any potential settled solids located within the wedge wire
screen.
3. Using a high pressure washer, the entire surface area of the wedge wire
screen is then washed to remove all embedded grit.
4. Any remaining grit still present after the high pressure wash will need to be
removed with the aid of a wire brush being applied in a brushing action over
the entire surface of the screen.
5. Once the wedge wire screen has been cleaned as described above, an
inspection is then done of the screen to ensure that the aperture size is within
size limitation of the carbon being used. The screen is inspected for any
damage that may have occurred during operation and handling.
6. The gap between the wedge wire screen and rotating cage must be inspected
to ensure that the gap is uniform around the circumference and length of the
screen (as shown in figure 50).

Figure 49 Opening of the Hydraulic Leg Drainage Port using the wrench tool

Figure 50 Clearance gap inspection between screen and rotating cage

GAP
GAP

Page64

9.1.2 Maintenance and Inspection of the Drive Unit.

The drive unit consists of the gearbox, gearbox motor adaptor and electric motor.
The maintenance and inspection of the drive unit consists of monitoring the gearbox
oil levels and lubrication of the bearing for the gearbox motor adaptor and electric
motor every two weeks for each Interstage Screen in operation. For more information
on the maintenance and inspection of the gearbox and motor adaptor refer to section
18 of this manual. More information related to the maintenance and inspection of the
electric motor can be attained in section 11 of this manual. The specification of the oil
can be attained from section 19 of this manual.

9.1.3 Maintenance and Inspection of the Protective coatings of Entire
Interstage Screen Assembly.

During the maintenance and inspection procedure of the wedge wire screen
indicated in section 9.1.1, additional time should be taken for the inspection of the
condition of the protective coatings that have been applied to the Interstage Screen.
The recommended inspection procedure is as follows:

1. Using a high pressure washer, clean off all soiled areas of the entire
Interstage Screen assembly.
2. A thorough inspection of all the rubber lined and painted surfaces should be
conducted and any corroded/abraded areas should be repaired. This is done
using a rubber lining repair kit or touch-up paint depending on the corrosion
protected surface being repaired.
3. Before the damaged surface is repaired, actions should be taken to ensure
that the repaired surfaces are clear of dust, moisture and surface rust.


Page65

9.2 Maintenance and Inspection Procedure during Storage

Whilst the Kemix Interstage Screen is placed out of operation or in storage, the
following procedures must be taken to protect the equipment:

9.2.1 Maintenance and Inspection of the Drive Unit during Storage

The following storage procedures are in accordance with the gearbox and motor
supplier recommendations:

1. Gearbox and motor assembly are required to be rotated past one complete
revolution once every month.
2. Gearbox assembly are required to be stored away from direct sunlight to
avoid any significant temperature increases in the oil and grease.
3. The motor and gearboxes are required to be stored away from any sources of
vibration for example railway lines, forklifts, blasting etc.
9.2.2 Maintenance and Inspection of the Entire Interstage Screen Assembly
during Storage

The following storage procedures are to be implemented for the entire Interstage
Screen assembly:

1. It is recommended that the Interstage Screen part assembly be stored
indoors to avoid damage to the natural rubber lining caused from
extensive exposure to UV direct sunlight.
2. The Interstage Screens should be stored in an area that is away from any
grinding or welding activities to ensure that no weld splatter or grinding
sparks contaminate the Interstage Screen protective coating.


Page66

10 SPARES REPLACEMENT PROCEDURES

The most common of the spare parts that will require to be replaced is the
replacement of the wedge wire screen. This under a good a maintenance schedule
will be required to be replace between 9 and 12 months depending on the nature of
the pulp being treated. The replacement procedure for the wedge wire screen is
detailed below. A list of tools required is given in section 13. All bolts should be
torqued to the values specified in section 12.
10.1 Wedge-Wire Screen Replacement

The wedge wire screen may be replaced by the reverse procedure of assembling the
Interstage Screen and must be performed in a maintenance bay as follows:

1. The Interstage Screen must first be mounted in a maintenance bay (refer to
section 7).
2. The weight of the agitator (located at the bottom of the Interstage screen), must
then be supported by using nylon slings and chain blocks which are used to
secure the agitator to the maintenance bay structure (refer to figure 51).
3. Once it has been ensured that the agitator is well supported, remove the agitator
by removing the bolts through the agitator flange, rotating cage hub and first shaft
lower flange. The centre bolt located in the center of the rotating cage hub which
secures the rotating cage and shaft together will prevent the rotating cage from
dropping.
4. The agitator can now be lowered and removed.
5. The weight of the rotating cage must now be supported by using the nylon slings
and chain blocks which are used to secure the rotating cage to the maintenance
bay structure (refer to figure 52). Care should be taken not to damage the rotating
cage during this procedure.
6. Once it has been ensured that the rotating cage is well supported, remove the
centre bolt located in the center of the rotating cage hub which secures the
rotating cage and shaft together.
7. The rotating cage can now be carefully lowered and removed, making sure not to
damage any coatings.
8. A temporary bracket, similar to that shown in figure 53, must now be bolted to the
1
st
shaft lower flange to support the hydraulic leg.
9. The weight of the wedge wire screen and hydraulic leg must then be taken up by
using slings and chain blocks which are used to secure the wedge wire screen
and hydraulic leg to the maintenance bay structure (refer to figure 54).
10. Once it has been ensured that the wedge wire screen and hydraulic leg is well
supported, remove the bolts in the wedge wire screen top flange.
11. Lower the wedge wire screen and hydraulic leg until the hydraulic leg rests on the
temporary bracket attached to the shaft flange.
12. The weight of the wedge wire screen must then be taken up by using slings and
chain blocks which are used to secure the wedge wire screen to the maintenance
bay structure.
13. Once it has been ensured that the wedge wire screen is well supported, remove
the fasteners in the wedge wire screen bottom flange and lower the wedge wire
screen and remove. The hydraulic leg will remain behind supported on the
temporary bracket attached to the shaft flange.
14. The new wedge wire screen can now be fitted in the reverse order to that of
above.


Figure 51 Supporting the Agitator using Nylon Slings and Chain Blocks

Figure 52 Supporting the Rotating Cage using Nylon Slings and Chain Blocks

CHAIN
BLOCK
NYLON
SLINGS
NYLON
SLINGS
CHAIN
BLOCK
Figure 53 - Hydraulic leg support bracket

Figure 54 Supporting the Wedge Wire Screen and Hydraulic Leg using Nylon
Slings and Chain Blocks
NYLON
SLINGS
CHAIN
BLOCK

Page69

11 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR
ELECTRIC MOTORS

11.1 Receiving Check

Check if any damage has occured during transportation.
Check nameplate data.
Remove shaft locking device (if any) before operating the motor.
Turn the shaft with the hand to make sure if it is turning freely.

11.2 Handling and Transportation

NOTE: MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYE
BOLTS WHICH ARE PROPERLY DESIGNED TO SUPPORT THE
MOTOR WEIGHT.

Lifting devices, when supplied, are designed only to support the motor. If the motor
has two lifting devices then a double chain must be used to lift it. Lifting and lowering
must be done gently without any shocks, otherwise the bearings can get damaged.

NOTE: DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR
ANGULAR CONTACT BEARINGS ARE PROTECTED AGAINST
BEARING DAMAGES WITH A SHAFT LOCKING DEVICE.

NOTE: THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER
TRANSPORT OF THE MOTOR, EVEN WHEN THIS MEANS TO
UNCOPULE THE MOTOR FROM THE DRIVEN MACHINE.

11.3 Storage

If motors are not immediately installed, they must be stored in dry places, free of
dust, vibrations, gases, corrosive smokes, under constant temperature and in normal
position free from other objects.

In case the motors are stored for more than two years, the bearings must be
changed or the lubrication grease must be totally replaced after cleaning.

Single phase motors when kept in stock for 2 years or more must have their
capacitors replaced (if any).

We recommend to turn the shaft (by hands) at least once a month, and to measure
the insulation resistance before installing it, in cases of motors stored for more than
6 months
or when subject to high humidity areas.

If motor is fitted with space heaters, these should be
switched on.


Page70

11.4 Insulation Resistance Check

Measure the insulation resistance before operating the motor and/or when there is
any sign of humidity in the winding.

The resistance measured at 25C (77F) must be:

Ri >(20 x U) / (1000 +2P) [Mohm] (measured with a MEGGER at 500 V
d.c.);

Where: U =voltage (V)
P =power (kW)

If the insulation resistance is less than 2 megaohms, the winding must be dried
according to the following:

Warm it up inside an oven at a minimum temperature of 80C (176oF) increasing 5C
(41oF) every hour until 105C (221oF), remaining under this temperature for at least
one hour. Check if the stator insulation resistance remains constant within the
accepted values. If not, stator must be reimpregnated.
11.5 Installation
11.5.1 Safety

All personnel involved with electrical installations, either handling, lifting, operation or
maintenance must be well informed and up-to-dated concerning the safety standard
and
principles that govern the work and carefully follow them. We strongly recommend
that these jobs are carried out by qualified personnel.

NOTE: MAKE SURE THAT THE ELECTRIC MOTORS ARE SWITCHED OFF
BEFORE STARTING ANY MAINTENANCE SERVICE.

Motors must be protected against accidental starts. When performing any
maintenance service, disconnect the motor from the power supply. Make sure all
accessories have been switched off and disconnected. Do not change the regulation
of the protecting devices to
avoid damaging.

NOTE: LEAD CONNECTION IN SULATION INSIDE THE TERMINAL BOX
MUST BE DONE WITH AN INSULATING MATERIAL COMPATIBLE
WITH MOTOR THERMAL CLASS WHICH IS SHOWN ON THE MOTOR
NAMEPLATE.

11.5.2 Operating Conditions

Electric motors, in general, are designed for operation at an altitude of 1000m above
sea level for an ambient temperature between 25C (77F) and 40C (104F). Any
variation is stated on the nameplate.


Page71

NOTE: COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED,
OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION
WITH THE DATA GIVEN ON THE NAMEPLATE.

Motors supplied for hazardous locations must be installed in areas that comply with
that specified on the motor nameplate.

NOTE: KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN
OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE
BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND OF
THE INLET OPENING DIAMETER.

11.5.3 Foundation

Motors provided with feet must be installed on though foundations to avoid excessive
vibrations. The purchaser is fully responsible for the foundation. Metal parts must be
painted to avoid corrosion. The foundation must be uniform and sufficiently tough to
support any short circuit strengths. It must be designed in such a way to stop any
vibration originated from resonance.

11.5.4 Drain Holes

Make sure the drains are placed in the lower part of the motor when the mounting
configuration differs from that specified on the motor purchase order.

11.5.5 Balancing

NOTE: KEMIX MOTORS ARE DYNAMICALLY BALANCED, WITH HALF KEY
AT NO LOAD AND UNCOUPLED.

Transmission elements such as pulleys, couplings, etc must be dynamically balanced
with half key before installation. Use always appropriate tools for installation and
removal.

11.5.6 Alignment

NOTE: ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING,
WHENEVER POSSIBLE.

Ensure that the motor mounting devices do not allow modifications on the alignment
and further damages to the bearings. When assembling a half-coupling, be sure to
use suitable equipment and tools to protect the bearings.

Suitable assembly of half-coupling: check that clearance Y is less than 0.05mm and
that the difference X1 to X2 is less than 0.05m as well.

Note: TheX dimension must be at least 3mm.


Page72

Figure 55 - Suitable assembly of half-coupling

11.5.7 Belt Drive

When using pulley or belt coupling the following must be observed:

Belts must be tighten just enough to avoid slippage when running, according to the
specifications stated on the belt supplier recommendation.

WARNING: Excessive tension on the pulleys will damage the bearings and lead
to a probable shaft rupture.
11.5.8 Connection

WARNING: Voltage may be connected at standstill inside the terminal box for
heating elements or direct winding heating.

WARNING: The capacitor on single-phase motors can retain a charge which
appears across the motor terminals, even when the motor has
reached standstill.

NOTE: A WRONG CONNECTION CAN BURN THE MOTOR.

Voltage and connection are indicated on the nameplate. The acceptable voltage
variation is 10%, the acceptable frequency variation is 5% and the total
acceptable variation is 10%.
11.5.9 Starting Methods

The motor is rather started through direct starting. All Kemix motors must be
connected as shown on the motor nameplate, failure to follow the motor nameplate
could lead to motor failure. In case this is not possible, use compatible methods to
the motor load and voltage.

3 lead single voltage and 9 lead dual voltage motors can be started as follows:

Full Voltage Direct On Line.
Auto-Transformer Starting.
Electronic Soft-Starting.

Page73

VFD Starting - subject to verification and application analysis.

6 lead single voltage motors and 12 lead dual voltage motors can be connected as
follows:

Full Voltage Direct On Line.
WYE/DELTA Starting.
Auto-Transformer Starting.
Electronic Soft-Starting.
VFD Starting - subject to verification and application analysis.

The rotation direction is clockwise if the motor is viewed from DE side and if the
phases are connected according to the sequence L1, L2, L3. To change the rotation
direction, interchange two of the connecting leads.

NOTE: THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY
QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A
SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE
MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL
BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.

Make sure to use the correct cable dimension, based on the rated current stamped
on the motor nameplate.

NOTE: BEFORE ENERGIZING THE TERMINALS, CHECK IF THE EARTHING
IS MADE ACCORDING TO THE ACTUAL STANDARDS. THIS IS
ESSENTIAL AGAINST ACCIDENT RISKS.

When the motor is supplied with protective or monitor temperature device such as
thermostats, thermistors, thermal protector, etc, connect their terminals to the
corresponding
devices on the control panel.

11.5.10 Start-Up

NOTE: THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING
THE MOTOR.

a) The motor must start and operate smoothly. In case this does not occur, turn it off
and check the connections and the mounting before starting it again.
b) If there is excessive vibration, check if the fastening screws are correctly
fastened. Check also if the vibration comes from a neighbour machine. Periodical
vibration checks must be done.
c) Run the motor under rated load for a short period of time and compare if the
running current is equal to that stamped on the nameplate.


Page74

11.6 Maintenance

WARNING: SAFETY CHECK LIST.

11.6.1 General Inspection

Check the motor periodically.
Keep the motor clean and assure free air flow.
Check the seals or V Ring and replace them, if required.
Check the connections as well as supporting screws.
Check the bearings and observe:
Any excessive noise, bearing temperature and grease condition.
When a changing, under normal conditions, is detected, check the motor and
replace the required parts.
The frequency of the inspections depends on the motor type and on the
application conditions.
11.7 LUBRICATION

NOTE: FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL
FOR PROPER MOTOR OPERATION.
11.7.1 Machines without Grease Nipples

Motors up to frame 324/6T are normally fitted without grease nipples. In these cases
the regreasing shall be done at the preventive maintenance job observing the
following aspects:

Disassemble carefully the motors.
Take all the grease out.
Wash the bearing with querosene or diesel.
Regrease the bearing immediately.
11.7.2 Machines Fitted with Grease Nipples

It is strongly recommended to grease the machine while running. This allows the
grease renewal in the bearing housing. When this is not possible due to turning parts
by the grease
device (pulleys, bushing, etc) that offer some risk to the physical integrity of the
operator, proceed as follows:

Clean the area near to the grease nipple.
Put approximately half of the total grease and run the motor for 1 minute at full
speed. Then turn off the motor and pump the rest of the grease.
The injection of all the grease with the motor in standstill can make the grease
penetrate into the motor, through the inner seal of the bearing housing.

When regreasing, use only special bearing grease with the
following properties:

Page75

Table 3 - Relubrication Intervals Recommended - Polyrex Em Grease (Esso/Exxon)

Frame
Amount of
Grease (g)
3600 rpm 3000 rpm 1800 rpm 1500 rpm 1200 rpm 1000 rpm 900 rpm 750 rpm 720 rpm 600 rpm 500 rpm
254/6T 13 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000
284/6T 18 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000
324/6T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000
364/5T 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
404/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
444/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
504/5TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
586/7TS 27 3600 4500 9700 11600 14200 16400 17300 19700 20000 20000 20000
324/5T 21 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000
364/5T 27 9700 11600 14200 16400 17300 19700 20000 20000 20000
404/5T 34 6000 7600 9500 11600 13800 15500 15500 17800 20000
444/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000
447/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000
504/5T 45 4700 6000 7600 9800 12200 13700 13700 15700 20000
Relubrication intervals in hours - ball bearings
Relubrication intervals in hours - cylindrical roller bearings

Page76

WARNING: The table above is specifically intended for relubrication with
PolyrexEM grease and bearing absolute operating temperature
of:

70oC (158oF) for 254/6T to 324/6T frame motors;
85oC (185oF) for 364/5T to 586/7T frame motors.

For every 15oC (59oF) above these limits, relubrication interval must be reduced by
half. Shielded bearing (ZZ) are lubricated for berings life as long as they operate
under normal ambient conditions and temperature of 70C(158oF ).

NOTE: WE RECOMMEND TO USE BALL BEARINGS FOR MOTORS
DIRECTLY COUPLED TO THE LOAD.

WARNING: EXCESS OF GREASE CAN CAUSE BEARING OVERHEATING
RESULTING IN COMPLETE DAMAGE.

11.7.3 Compatibility of Polyrex
EM grease with other types of grease

Containing polyurea thickener and mineral oil, the Polyrex
EM grease is compatible
with other types of grease that contain:

Lithium base or complex of lithium or polyurea and highly refined mineral oil;
Inhibitor additive against corrosion, rust and anti-oxidant additive.

Notes:

Although PolyrexEM is compatible with the types of grease given above, we do
no recommend to mix it with any other greases.
If you intend to use a type of grease different than those recommended above,
first contact Kemix.
On applications (with high or low temperatures, speed variation, etc), the type of
grease and relubrication interval are given on an additicional nameplate attached
to the motor.
Vertical mounted motors must have the relubrication intervals reduced by half.

NOTE: THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL
APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE
MANUFACTURER OR KEMIX.

11.8 ASSEMBLY AND DISASSEMBLY

Disassembly and assembly must be done by qualified personnel using only suitable
tools and appropriated methods. The stator grips must be applied over the side face
of the inner ring to be disassembled or over and adjacent part.


Page77

It is essential that the bearings disassembly and assembly be done under cleanning
conditions to ensure good operation and to avoid damages. New bearings shall only
be taken out from their cases when assembling them.

Before installing a new bearing it is required to check the shaft fitting for any sharp
edge or strike signals.

For bearing assembly, warm their inner parts with suitable equipment - inductive
process - or use suitable tools.

11.9 SPARE PARTS

When ordering spare parts, please specify the full type designation and product code
as stated on the motor nameplate. Please also inform the motor serial number stated
on the nameplate.

11.10 MOTORS FOR HAZARDOUS LOCATIONS

Besides the recommendations given previously, these ones must be also followed:

NOTE: THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR
CUSTOMERS RESPONSIBILITY, WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS.

Motors for hazardous locations are manufactured according to specific standards for
such environments and they are certified by worldwide certifying entities.

11.10.1 Installation

The complete installation must follow procedures given by the local legislation in
effect.

NOTE: THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE
CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL
PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR
OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT.

11.10.2 Maintenance

Maintenance must be carried out by repair shops authorized by Kemix. Repair shops
and people without Kemixs authorization who will perform any service or hazardous
location motors will be fully responsible for such service as well as for any
consequential damage.

NOTE: ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON
HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION.

When performing maintenance, installation or relubrication, follow these instructions:

Page78

Check if all components are free of edges, knocks or dirt.
Make sure all parts are in perfect conditions.
Lubricate the surfaces of the endshield fittings with protective oil to make the
assembly easier.
Use only rubber hammer to fit the parts.
Check for correct bolts tightening.
Use clearance calibrator for correct T-box fitting (smaller than 0.05mm).

NOTE: DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY
NEW ONES SUPPLIED BY THE FACTORY.

11.11 MOTORS DRIVEN BY VFD

Applications using VFDs without filter can affect motor performance as follows:

Lower efficiency.
Higher vibration.
Higher noise level.
Higher rated current.
Higher temperature rise.
Reduced motor insulation.
Reduced bearing life.

11.11.1 Standard Motors

Voltages lower than 440V do not require filter.
Voltages equal or higher than 440V or lower than 575V require filter for motor
power supply cables longer than 20 meters.
Voltages equal or higher than 575V require filter for any size of power supply
cables.

NOTE: IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED
ACCORDINGLY, MOTOR WARRANTY WILL BE VOID.

11.11.2 Inverter Duty Motors

Check power supply voltage of the forced cooling set.
Filters are not required.

11.12 WARRANTY TERMS - SERIES AND ENGINEERING PRODUCTS

Kemix warrants its products against defects in workmanship and materials for 18
months from the invoice date issued by the factory, authorized distributor or agent
limited to 24 months from manufacturing date independent of installation date as long
as the following items are fulfilled accordingly:


Page79

Proper transportation, handling and storage;
Correct installation based on the specified ambient conditions and free of
corrosive gases;
Operation under motor capacity limits;
Observation of the periodical maintenance services;
Repair and/or replacement effected only by personnel duly authorized in writing
by Kemix;
The failed product be available to the supplier and/or repair shop for a required
period to detect the cause of the failure and corresponding repair;
Immediate notice by the purchaser about failures occured and that these are
accepted by Kemix as manufacturing defects.

This warranty does not include disassembly services at the purchaser facilities,
transportation costs with product, tickets, accomodation and meals for technical
personnel when requested
by the customer. The warranty service will be only carried out at Kemix Authorized
Repair Shops or at Kemixs facilities.
Components whose useful life, under normal use, is shorter
than the warranty period are not covered by these warranty terms.
The repair and/or replacement of parts or components, when effected by
Kemix and/or any Kemix Authorized Repair Shop, will not give warranty extension.
This constitutes Kemixs only warranty in connection with this sale and the
company will have no obligation or liability whatsoever to people, third parties, other
equipment or installations, including without limitation, any claims for consequential
damages or labor costs.


Page80

12 BOLT TORQUE TABLE

All the bolts on the AAC Pumpcell mechanism should be torque to the values
specified in Table 4.

Table 4 - Steel Bolt Torque Table (Nm)
Grade
Size 4.6 8.8
12 38 68
16 95 185
20 185 360
24 320 620
30 600 1225
36 - 2343

Table 5 304 Stainless Steel Bolt Torque Table (Nm)
Size Torque (Nm)
12 38
16 95
20 185
24 320
30 600
36 1115

13 TOOLS REQUIREMENT

Full set of metric spanners. (Sizes 10 60)


Page81

14 TECHNICAL DRAWINGS 1 G.A OF AAC PUMPCELL
PLANT

Figure 56 - G.A. of AAC Pumpcell Plant


Page82

15 TECHNICAL DRAWINGS 1 G.A OF AAC PUMPCELL
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5
0
W
ID
T
H
O
F
V
O
L
U
T
E
O
P
E
N
IN
G
5
9
0
R
O
T
A
T
IO
N

( 1
2
0
) T
Y
P
2
3
2
5
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O
W
N
-P
U
M
P
IN
G
H
Y
D
R
O
F
O
IL
300
150
(1108)
RUBBER LINING
TO UNDERSIDE OF
TOP STRUCTURE
63
(643)
(900) RUBBER SEAL
225
1
8
5
0
R
O
T
A
IN
G
C
A
G
E
1
5
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0
S
C
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N
3 R
U
B
B
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R
L
IN
IN
G
C
O
M
P
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S
S
IB
L
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L
314
1
1
1
9
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H
IS
T
O
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Y
Z
O
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R
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S
C
R
IP
T
IO
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A
P
P
R
O
V
E
D

1

2
8
F
e
b
ru
a
ry
1
1

2

3
1
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a
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1
1

1 1
1
1
A
.J
E
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F
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2
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. 1
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6
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, F
R
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C
,
1
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IF
T
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M
7
T
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.J
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. 1
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. F
R
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A
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T
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C
;
1
A
.J
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F
F
R
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3
1
M
A
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. 1
1
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R
M
A
L
F
L
O
W
F
R
O
M
2
1
2
T
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3
&
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A
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2
8
0
T
O
3
3
0

Page83

16 TECHNICAL DRAWINGS 3 P & ID AND PFD

Figure 58 P & ID and PFD of AAC Pumpcell Plant


Page84

18 GEARBOX OPERATING INSTRUCTIONS
A.1 Gearbox technical operating instructions


Page85

19 LUBRICATION SCHEDULE
Lubrication Schedule for Gearbox Assembly and Electric Motor.

AAC Kemix Pumpcell Plant Operating Installation Manual - Yamana - Chile Minera Florida Limitada Project - Rev0

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AAC Kemix Pumpcell Plant Operating Installation Manual - Yamana - Chile Minera Florida Limitada Project - Rev0

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Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

EM grease with other types of grease ..................... 76

EM grease with other types of grease

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