Index Curve Catalogue Maintenance Manuals Drawing Information

CH Warman
PRODUCT
BULLETIN
Nº 20 OCTOBER 2004 PB20/Rev0

6/4 HIGH PRESSURE PUMP UPGRADE

INTRODUCTION

The pressure exerted by mining operations on the performance of slurry pumps is

increasing daily. This necessitated an upgrade on the 6/4EE-AHP (Abrasive Head
High Pressure) pump, now capable of withstanding an operating pressure of 50 bar.
This pump is now referred to as the 6/4EE-AHPP (Abrasive Head Ultra High
PPressure) pump. The upgrade involved the following :

· Structural upgrade on the Frame Plate and Cover Plate;

· Material upgrade on the Frame Plate, Cover Plate, Stuffing Box, Packing, Shaft
Sleeve and Cover Plate Bolts;
· Modification to the Cotters for better fitment;
· Different Stuffing Boxes for different liner materials.

PRESSURE RATING

Table 1 lists the increase in the allowable maximum operating pressure realised with
the upgrade of the structural components and their material of construction.
6/4EE-AHP 6/4EE-AHPP
ELASTOMER ELASTOMER
METAL LINED METAL LINED
(RUBBER) LINED (RUBBER) LINED
MAXIMUM OPERATING PRESSURE [bar]
34.5 34.5 50.0 50.0

The upgrade in the maximum allowable operating pressure makes the new ultra high
pressure pump especially suited to series pumping over long distances. It is now
possible to transport slurry over long distances without the necessity of having
transfer points along the pipe line to limit the pump casing pressure.
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STRUCTURAL UPGRADE

Frame Plate (EPP4032)

The Frame Plate stiffness was increased by adding four radial ribs between the
casing and mounting flange. The shape of these ribs was altered to add additional
strength. The maximum deflection takes place at the discharge branch area. This
was countered by increasing the casing thickness, as well as the thickness and
height of the three ribs supporting the discharge branch. Figure 1 shows a
comparison between the old and new pump Frame Plate.

Figure 1 : Structural enhancement of Frame Plate EP4032 (left) to EPP4032.

Cover Plate (EPP4013)

The Cover Plate stiffness was increase by adding four large radial ribs, extending
from the suction flange to the casing outer periphery. Similar to the Frame Plate, the
stiffness of the discharge branch was enhanced by increasing the casing thickness,
as well as the thickness and height of the three ribs supporting the discharge branch.
Figure 2 shows a comparison between the old and new pump Cover Plate.
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Figure 2 : Structural enhancement of Cover Plate EP4013 (left) to EPP4013.

MATERIAL UPGRADE

Frame Plate (EPP4032)

The Frame Plate material of construction was upgraded to D23 (SG70). D23 is 60%
stronger than D20 (SG42), the previous material of construction.

Cover Plate (EPP4013)

As with the Frame Plate, the Cover Plate material of construction was upgraded from
D20 to D23.

Stuffing Box (EP078 & EP078-1)

Due to the Stuffing Box also being exposed to the increased pressure, its material of
construction was upgraded from G01 (cast iron) to D23. This will ensure adequate
strength, even in the worn condition.

Shaft sleeve (EE076)

The Shaft Sleeve material of construction was upgraded from D20 to E62A. The
Shaft Sleeve is Stellite, coated, protecting it from rapid wear normally associated with
ultra high pressure duties.

Cover Plate Bolts (EP4015M)

The higher maximum allowable operating pressure increases the parting force
between the Cover and Frame Plate substantially. Accordingly the Cover Plate Bolt
material of construction was upgraded from E63 (1030 steel) to E81 (4140 steel).
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Packing (E111)

The Packing material of construction was upgraded from Q05A (normal acrylic) to
Q24A (Kevlar reinforced acrylic). This ensures that the packing maintains its shape
under the extreme pressure.

COTTER MODIFICATION

To ensure adequate sealing of the Throat Bush under the high pressure, the cotter
design was slightly altered. The metal and rubber lined pumps now use different
cotters. The metal lined pump uses cotter EH3085, and the rubber lined pump uses
cotter EPP4085.

DIFFERENT STUFFING BOXES - METAL AND RUBBER LINED PUMPS

Metal lined pumps

Stuffing Box EP078-1, previously used for both the Metal and Rubber lined pumps is
now exclusive to the Metal lined pump. This Stuffing Box uses an o-ring seal.

Rubber lined pumps

Rubber lined pumps now use Stuffing Box EP078. This stuffing box differs from the
Metal lined pump Stuffing box in terms of the sealing end. It does not use an o-ring
seal but has a special sealing face, pressing onto a seal integral to the Frame Plate
Liner. Figure 3 clearly illustrates the difference.

Figure 3 : Differences between the Metal (left) and Rubber pump Stuffing Boxes.
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INTERCHANGEABILITY

The new AHPP pump is fully interchangeable with the AHP pump. Table 2 lists the
part changes for Metal and Rubber pumps.

OLD OLD NEW NEW

QTY QTY DESCRIPTION
PART MATERIAL PART MATERIAL
PART AND MATERIAL CHANGE PART CHANGE ONLY MATERIAL CHANGE ONLY
EP4032 D20 1 EPP4032 D23 1 FRAME PLATE
EP4013 D20 1 EPP4013 D23 1 COVER PLATE
METAL LINED

E4085 E02 2 EH3085 E02 2 COTTER

E078-1 G01 1 E078-1 D23 1 STUFFING BOX
E111 Q05 1 SET E111 Q24 1 SET PACKING
EP4015M E63 12 EP4015M E81 12 COVER PLATE BOLT
EE076 D20 1 EE076 E62A 1 SHAFT SLEEVE
EP4032 D20 1 EPP4032 D23 1 FRAME PLATE
RUBBER LINED

EP4013 D20 1 EPP4013 D23 1 COVER PLATE

E078-1 G01 1 E078 D23 1 STUFFING BOX
E4085 E02 2 EPP4085 E02 2 COTTER
E111 Q05 1 SET E111 Q24 1 SET PACKING
EP4015M E63 12 EP4015M E81 12 COVER PLATE BOLT
EE076 D20 1 EE076 E62A 1 SHAFT SLEEVE

Existing users of the 6/4EE-AHP pump should note that in this case, the term
“Interchangeable” implies new parts fitting the old pump only. Old parts should never
be used with new AHPP pumps. This implies that existing users, when ordering
spares or replacement parts will be supplied with the new interchangeable parts only,
as the old parts were superseded. This decision was taken due to safety
considerations, as stated in the CH Warman Pump Group Policy, ensuring the supply
of equipment that is safe to operate. Customers should also note that options in
terms of the material of construction are still available. This excludes parts
associated with the structural integrity of the pump (Cover Plate, Frame Plate &
Stuffing Box).

CONCLUSION

The new 6/4EE-AHPP pump is ideally suited for heavy duty slurry pumping at high
pressures. It has a maximum operating pressure of 50 bar, compared to 34.5 bar of
its predecessor, enabling the end user to set even higher standards and meet them
successfully. Warman has once again proven their capability of honouring their
commitment to its customers in providing them with the best pumping solution
available. Refer to WDS106 for pressure ratings.