MechTech June 2016 Final

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⎪ Sustainable energy and energy management ⎪
to be monitored over time. This means
that replacements can be made before
excessive wear leads to sub-optimal
performance or failure.
Examining the condition of internal
parts such as the lining and impeller will
mean taking it out of action for a short
time. This is often worthwhile in order
to avoid unexpected repairs and long
periods of poor efficiency.
The frequency of these tests should
be determined based on a good knowl-
edge of the average operating lifespan of
individual parts at the relevant levels of
duty. This way, checks will be performed
frequently enough to maintain efficient
performance, but not more often than
necessary, avoiding excessive costs.
Non-interruptive monitoring should
also be carried out regularly, as this
provides a way for any issue arising
between scheduled checks to be noted.
Temperature and vibration measurement
of any moving parts, energy consump-
tion and flow-rate monitoring can all be
carried out while a pump is operational
– supplying useful information without
costly downtime.
All mechanical seals should also
be regularly checked and, if necessary,
adjusted – especially those around the
drive shafts of pumps.
Advanced monitoring systems are
available that use handheld devices
connected to a central database to guide
on-site personnel through the process.
This ensures that no part is missed and
that all monitoring data is stored cen-
trally so maintenance can be properly
prioritised across a whole site. In 2013,
Weir Minerals launched a proprietary
condition monitoring system, which is
used by its maintenance engineers and
is available to its customers. Many cases
have been seen where automating the
maintenance process at coal mining sites
has delivered a significant improvement
in equipment performance.
Systems, conditions and acceptable
performance margins vary between dif-
ferent sites, so there cannot be a standard
solution that meets the requirements of
all. Consulting with an equipment sup-
plier or maintenance expert is advisable
to ensure that the right level of monitoring
is in place.
It is Weir Minerals’ mission as a
pump manufacturer to deliver continuous
improvement
for its customers,
whether in terms of increases in energy
efficiency, reduction in the frequency with
which parts need replacing and the ease
with which this can be done.
It is important for those operating coal
processing plants to keep abreast of the
developments both in pump technology
and in the support strategies that many
suppliers are now beginning to adopt in
order to ensure that the pumps driving
their process are performing well.
Ultimately, fit-for-purpose pumps
running at optimum efficiency will bring
significant production benefits. q
A cutaway model of the Warman
froth pump with the modified
inducer impeller
blades.