Are you a maintenance supervisor struggling with pump breakdowns? Learn how we repaired a large Everflow pump for a major mine extracting copper, gold, and uranium. This case study will provide valuable insights that you can apply to your own pump repair process.
The Challenge
A leading mining company with extensive copper, gold, and uranium deposits contacted us to troubleshoot a leaking Everflow pump. The pump had the following specifications:
- Capacity: 200 GHH
- Stages: 4
- Motor: 45 kW
Their maintenance supervisor reported water leaking from the gland packing.
A Look Inside Our Tonsley Workshop (at 12 Selgar Ave)
The Solution
The pump was shipped to our workshop for a complete inspection. Upon initial examination of the reported gland packing leak, we discovered more extensive issues:
- Pump Wet End: The wet end (impeller section) was disassembled, cleaned, and evaluated. We found significant shaft wear and the need to replace all rubber bearings. The impellers and housing remained in good condition. These worn components were replaced, and the wet end was reassembled.
- Pump Head: A thorough cleaning and inspection of the pump head revealed a worn head shaft, corroded packing box assembly (including the gland follower) and seized thrust bearings. We replaced all these components with new gland packing and a bronze bearing.
- Motor: The motor was disassembled, cleaned, and inspected. Worn bearings, deteriorated coupling pin rubbers, and failing lip seals were identified. All these components were replaced, and the motor was reassembled. A qualified electrician also performed a comprehensive electrical check.
Final Assembly and Testing:
After reassembling the pump, pump head, and motor, we meticulously set the impeller clearances. The pump was then rigorously tested in our tank, reaching its maximum flow rate of 90 litres per second. The test confirmed quiet operation, no leaks, and overall functionality. Finally, the entire pump assembly was given a two-pack epoxy paint finish before being shipped back to the customer.
The Result
The repaired pump has been seamlessly integrated back into their mining operations, likely used on bores for pumping water from underground and probably supplying water to be used in the mining process.
This pump repair process involved comprehensive inspections, purchase order processing, and installation of the required spare parts.
Facing pump challenges?
Our team of experts across South Australia, Victoria, Queensland, New South Wales, and Western Australia is ready to help. We'll assist with maintenance plans, troubleshoot failures, and assess if a new mining pump is a better long-term solution. Contact us here.
