Chapter 3. Mine Pumps

Chapter 3. Mine Pumps

ROBERT W. LAWSON

INTRODUCTION

Prior to 1705, underground mining was limited to mineral deposits located above or a very small distance below the water table. The development of the steam- driven mining pump was motivated by the need to ex- tract minerals from deposits considerably lower than the water table. Today, the majority of mine pumps are driven by electric motors, although some small utility pumps are driven by compressed air.

Of the numerous types of pumps that might be applied to mine service, the two types used most frequently underground are the centrifugal and plunger pumps. Each of these types has its proper application. In most instances, plunger pumps are best for handling low water volumes against high heads, while centrifugal pumps effectively handle either low or high water volumes against low heads or high water volumes against high heads.

This chapter describes pumps applied to under- - - -

ground mine service, where the mine service consists of mine drainage (removing mine water as it accumulates), mine dewatering (removing water from a flooded mine), and pumping for special applications such as hydraulic mining and hydraulic hoisting.

CENTRIFUGAL AND PLUNGER PUMPS

Modern mine pumps are classified as either centrifugal (kinetic) or plunger (positive-displacement) pumps. The following paragraphs describe each of these classifications.

Centrifugal Pumps Centrifugal pumps may be grouped into various

types, depending upon their various features: Number of Stages: In a single-stage pump, the total

head is developed by one impeller, while a multi- stage pump utilizes two or more impellers acting in one casing to develop the total head. Fig. 1 shows a cutaway view of a single-stage horizontal split-case double-

Fig. 1. Cutaway view of a single-stage horizontal split- case double-section centrifugal pump (courtesy of Inger-

soll-Rand Co.).

section centrifugal pump. Fig. 2 shows a cutaway view of a six-stage medium-pressure split-case diffuser-type centrifugal pump.

Type of Casing: A volute pump has a casing in the form of a spiral or volute. A circular-casing pump has a casing of constant cross section concentric with the impeller. A diffuser pump is equipped with a diffuser that converts velocity head to pressure head.

Shaft Position: A horizontal pump normally has the shaft in a horizontal position, while a vertical pump normally has the shaft in a vertical position. Fig. 3 illustrates a vertical turbine-type slurry pump.

Suction: A single-suction pump equips the first stage with a single-suction impeller, with fluid entering the impeller on only one side. A double-suction pump equips

Fig. 2. Cutaway view of a medium-pressure split-case six-stage diffusor-type centrifugal pump (courtesy of Ingersoll- Rand Co.).

1336

ANCILLARY EQUIPMENT

Fig. 7. Cross section of a Mitsubishi-MarsTM plunger-type slurry-pump system (courtesy of Mitsubishi Co.).

gravity of the mine water, H is the total dynamic head in feet, E, is the efficiency of the pump, and E , is the efficiency of the motor.

Suction Sump: The suction sump serves two important functions. First, the suction sump provides storage capacity in the event of a power outage or a mechanical failure of the pumping equipment. Many mines have established definite minimum storage limits. For example, Butte copper mines require that no pump installation have less than 4 hr storage of water inflow in the sump. In other mines, 45 to 90 min of storage is considered adequate, with local conditions dictating the storage capacity. Furthermore, the capacity of the storage sump should be adequate to accommodate any sudden inrush of water.

The second function of the suction sump is to provide adequate residence time for the suspended solids to settle, and the sump must be designed to allow removal of the residue. Many arrangements are in use, and Fig. 8 illustrates one possible arrangement.

The horizontal sump is the most prevalent, and it requires minimum shaft depth. It accommodates a horizontally split pump located in a dry well with flooded suction. The vertical sump, commonly used in South Africa, permits the residue to be drained by gravity from the bottom of the sump directly into a mud skip used to hoist the residue to the surface. How- ever, a vertical sump. requires a greater shaft depth than does a horizontal sump. It is well suited to the use of a vertical mine pump.

To determine the proper residency time in the sump, a number of mine-water samples should be placed in a laboratory graduate where the settling can be observed and timed. As a general approximation, a sump should have approximately 0.09 m2 (1.0 sq ft) of surface area for each 3.79 L (1.0 gal) pumped. This calculates to a settling rate of 0.68 mm/s (1.6 ipm). In designing either a vertical or a horizontal sump, an effort normally is made to direct the incoming water toward the bottom of the sump, taking the effluent from the top. The up-

ward rate of water flow should be less than the measured settling rate. In a horizontal sump, submerged weirs improve the effectiveness of solids removal, but such weirs should be designed so they do not hamper clean- ing the residue from the bottom of the sump.

The cost of providing adequate sump capacity is recovered many times over through reduced pump maintenance. The importance of removing abrasive solids from the mine water increases as the head against which the pump operates increases.

Mine-Pump Motors: Modern mine-pump motors are predominantly a-c induction motors. The type of motor enclosure is dictated by the conditions prevailing at the pump location. High-voltage current for major pump installations is transmitted by cables down the shaft or through boreholes and is transformed adjacent to the pump station to meet the requirements of the pump motor. The pump-motor voltage is selected according to economic considerations, including the cost of the transforming equipment, the motor-control equipment, and the motors.

Small utility pumps of approximately 7.6 L/s (120 gpm) and 45.7 m (150 ft) total head may operate on 689 kPa (100 psi) of compressed air, consuming approximately 0.019 m3/s per kW (30 cfm per hp).

Ventilation: Ventilation is an important consideration for any underground pump installation. Some mine waters release noxious gases that must be diluted and exhausted from the mine by means of adequate ventilation. More frequently, ventilation must be provided to remove the heat emitted by the pump motors and transformers. The total electrical energy supplied to the pump motors less the energy required to lift the water against the head is converted to heat; this may be calculated from the equation:

E = (56.92 X P ) -(0.011 X F X L,)

where E is the heat in British thermal units per minute, P is the power in kilowatts, F is the water flow rate in gallons .per minute, and L, is the static lift in feet.

UNDERGROUND MINING METHODS HANDBOOK

Fig. 8. Diagram of a horizontal sump showing details of the settler section (courtesy of H.L. Monroe).

The heat must be dissipated by either ventilation air or transferring the heat to the mine water pumped to the surface. One method of transferring the motor heat to the mine water is to enclose the pump motor so that the air circulated over the rotor and stator is in a closed system. This air then passes over a water-cooled heat exchanger before being recirculated through the motor, and the warmed water from the heat exchanger is dumped into the pump suction and transported to the surface.

Materials of Construction: The materials of construction are critical to the success of a pumping installation. The "wetted parts" in contact with the pumped liquid must be constructed of materials that resist corrosion and abrasion. For mine water with a neutral pH, a regular fitted pump with a cast-iron casing and a bronze impeller, wearing rings, and shaft sleeve is satisfactory. For slightly acid mine water, an all-bronze pump, sometimes called "admiralty metal," is the best construction. As the corrosive nature of the pumped water increases, it may become necessary to use chrome- nickel alloy. The pump manufacturer should be con- sulted for recommendations; the information that should be supplied to the pump manufacturer for proper selection of the pump materials includes: (1 ) the liquid to be pumped; (2) the principal corrosives; (3) the pH and specific gravity of the mine water; (4) the undissolved impurities and other constituents, including the specific gravity of the solids, the percentage of solids in the liquid by weight, and the particle size and distribution; (5) details of the expected pump service; (6) the materials

used for pipelines; and (7) any previous experience with materials of construction.

To accurately assess the performance of various materials, the pump manufacturer may request a sample of the mine water. When the mine water is corrosive and circumstances permit, the most accurate method of evaluating alloys is to place weighed "tabs" of likely alloys in a moving stream of mine water. At intervals, the weight loss is determined for each sample alloy.

When the mine water presents a serious operating problem, the most practical solution may be to treat the water in the sump before it is pumped. Such treatment could involve neutralizing the liquid with lime or some other additive or increasing the acidity with sulfuric acid to discourage the deposition of ocher in the pump columns. The economics of such treatment procedures must be analyzed for each individual installation.

It has been observed that pump maintenance caused by abrasive particles in the mine water has increased markedly when a mine has been converted from rail haulage to rubber-tire haulage. This is attributed to the rubber-tired vehicles constantly agitating the drainage water in the haulageways. If rubber-tired haulage is used, extra capacity for settling the solids should be provided in the sumps and a higher pump-maintenance cost anticipated.

Bid Form: The use of a bid form is suggested when requesting quotations from various pump manufacturers. Table 1 lists the items that should be included on such a form. The portion of the form listing the design conditions should be completed by the mine engineer and

ANCILLARY EQUIPMENT

Table 1. Suggested Items for a Bid Form

Project: Date: Purchaser: Ref. No.: Address:

Dealgn Condltlona Quantity Service Liquid Temperature, "C ("F) Capacity, Us (gpm) Max Discharge Pressure, kPa (psi) Max Suction Pressure, kPa (psi) Differential Pressure, kPa (psi) Specific Gravity Total Head, m (ft) Viscosity or Slurry Density pH Value Performance Pump Selection Speed, radls (rpm) Efficiency at Design Power, DesignIMax, kW (bhp) NPSH, AvailableIRequired, m (ft) Performance Curve Construction Packing or Seal Gland Type Piping Seal Flange Rating, SuctionIDischarge BearingdLubrication Trico Oilers Coupling Coupling Guard Bed plate Gage TapdVentslDrains Rotation (Viewed from Coupling End) Materlala Casing Impeller Shaft Shaft Sleeve Wearing Rings, ImpellerICasing Drlver TypeIFramelManufacturer Power, kW I radls (hplrpm) Rotation (Viewed from Opposite Coupling) Furnished ByIManufactured By Conditions Prlclng Shipping Weight, PumpIDriver, kg (Ib) Pump Shipment, weeks Net Pump Price, Each

-1 -1 - - CW CCW

-1-1- CW CCW

-1-1- CW - CCW

-1-1- I

- CW - CCW I

CW - CCW I

- CW CCW --I

the balance of the form should be completed by the vendor. The use of such a form facilitates comparing bids received from various manufacturers, and it assists the purchaser in making sure that the comparison is between equipment of comparable construction and performance. Overall, the use of such a form helps elimi- nate misunderstandings.

Pump Pefiormance Curves: Pump performance curves are the most convenient method of indicating the operating characteristics of a centrifugal pump. Fig. 9 illustrates the pump performance curve for a typical two-stage single-suction centrifugal pump.

If the system curve of the mine-pump installation is plotted with the same ordinate and abscissa scales as used for the pump performance curve, the two curves

may be superimposed as shown in Fig. 10. The system curve consists of the static head plus the friction head. The point at which the system curve crosses the head- capacity curve is the operating point for the installation.

As an example, assume that a two-stage single- suction pump is driven by a 56-kW (75-hp) electric motor at 372 rad/s (3550 rpm). The pump is fitted with a 241-mm (9.5-in.) diam first-stage impeller and a 216-mm (8.5-in.) second-stage impeller. The static head on the pump is 168 m (550 ft) , and pumping is into a 102-mm (4.0-in.) standard-weight steel pipe. The pipe length is a total of 274 m (900 ft) , including equivalent lengths for fittings. Fig. 10 shows that the operating point is at 15.8 L/s (250 gpm), with 183 m (600 ft) of head [I68 m (550 f t ) of static head plus 15

1342 UNDERGROUND MINING METHODS HANDBOOK

2 4

1 0 0 0 2 0 + W

IJ. 8 0 0 16 Z

9 6 0 0 12

I

2 4 0 0 8 + 0 +

2 0 0 I 0 0

7 5

5 0

25

0 4 0 8 0 120 160 2 0 0 2 4 0 2 8 0 3 2 0 360 4 0 0

GALLONS PER MINUTE

2 4

1 0 0 0 2 0 + W C IJ.

8 0 0 I6 1 Z (0

9 6 0 0 Z

12 I

4 0 0 8 + 0 + 9

2 0 0 I 0 0 , 7 5 : 5 0 7 25 $

0 4 0 8 0 120 160 2 0 0 2 4 0 2 8 0 3 2 0 360 4 0 0

GALLONS PER MINUTE

Fig. 9. Pump-performance curve for a typical two-stage Fig. 10. Pump-performance curve with a super-imposed single-suction centrifugal pump. Metric equivalents: ft X system curve. Metric equivalents: ft X 0.3048 = m; 0.3048 = m; in. X 25.4 = mm; gpm X 0.063 090 2 = in. X 25.4 = mm; gpm x 0.063 090 2 = L/s; bhp x

L/s; bhp X 0.745 699 9 = kW. 0.745 699 9 = kW.

m (50 ft) of friction head]. The pump efficiency is 63% and the power is 45.5 kW (61 bhp). The pump requires a minimum of 4.0 m (13 ft) net positive suction head (NPSH) .

For mine drainage or dewatering, a pump should have a head vs. capacity curve that rises constantly to shutoff. If this curve has a "hump," the pump may surge under certain operating conditions. Since the total dynamic head of a mine-drainage system is fairly constant, a reasonably flat curve is desirable. As water accumulates in the pump-section sump, the capacity handled by the pump increases because the suction head increases. That reduces the total dynamic head.

For a mine-dewatering pump, where the total dynamic head increases as the water in the mine recedes, a steep head vs. capacity curve is desirable. As the head increases, the capacity does not decrease significantly.

In selecting a pump, it is important to pick one with a characteristic curve that permits the anticipated operating-condition point to be close to the maximum pump efficiency. That is for reasons of both mechanical performance and power economy. Continuously operating a pump at an extreme above or below the point of maximum efficiency may cause unbalanced dynamic forces that can result in excessive flexing of the pump shaft, an overload on the pump bearings, and separation cavi- tation damage in the impellers.

The performance of a centrifugal pump with a given impeller design may be altered by changing the peripheral or tip speed of the impeller: (1) the capacity varies in direct relationship to the peripheral speed, (2) the head varies in direct relationship to the square of the peripheral speed, (3) the power varies in direct relationship to the cube of the peripheral speed, and (4) the efficiency remains constant for small changes in the peripheral speed. The peripheral speed may be changed by altering the diameter of the impeller or the rpm of the pump.

However, there are some limitations. Only a radial- flow centrifugal pump impeller can be altered, and too great a change alters the characteristics so that the performance does not conform to the relations stated. The impeller should not be cut so small that the vanes do not overlap. Otherwise, the performance may become

unstable. Too large an impeller in a casing interferes with the flow at the cutwater and reduces the overall efficiency of the pump.

Net Positive Suction Head (NPSH): The NPSH is the absolute pressure in meters (feet) above the vapor pressure of the liquid being pumped. The NPSH is measured at the pump suction flange on a gage mounted at the centerline of the pump. The available NPSH is the sum of the suction gage reading and the atmospheric pressure minus the vapor pressure. In equation form, this is expressed as:

NPSH = 2.3 1 (Pa + P, - vp - fs)

where NPSH is the net positive suction head in feet, Pa is the atmospheric (barometric) pressure in pounds per square inch, P, is the suction pressure in pounds per square inch at the pump suction nozzle corrected to the pump's horizontal centerline (if this is a suction lift, this is a negative value), vp is the vapor pressure in pounds per square inch, and fs is the friction loss in the suction piping in pounds per square inch. The 2.31 value is a constant to convert pounds per square inch to feet of water. The same relationship may be applied to values using metric units.

At sea level, the theoretical maximum suction lift of a pump is 10.4 m (34 ft) and indicates the distance from the surface of the water to the centerline of the pump. In practice, a suction lift of 6.1 m (20 ft) should not be exceeded. At altitudes above sea level, the suction lift should be reduced to correspond to the reduction in atmospheric (barometric) pressure. Most pump performance curves indicate the NPSH required by the pump. The available NPSH calculated from the equation always must be equal to or greater than the required NPSH.

Mine-Pump Cost

After reliability, the cost of the mine pump is the most important consideration in the selection process. The cost considered should be the total cost for the entire life of the pump. This total cost includes the purchase price, freight, installation costs, power costs, and maintenance costs. Over the life of the pump, the purchase price is only a small increment of the total

ANCILLARY EQUIPMENT

cost, and the costs for power and maintenance should be evaluated carefully.

As already indicated, the reliability of the pump installation probably is the most important consideration. If the mine is flooded, loss of production plus all of the costs related to reopening the mine far exceed the cost of the pumping equipment. In critical locations, standby equipment must be considered. For cost cal- culations, a ten-year life for the pump and accessories is an acceptable estimation. That "life" frequently is used when calculating equipment depreciation.

First Cost: The first cost is the purchase price of the equipment. This cost may be obtained from the equipment supplier. In recent years, prices have been fluctuating so widely that it is hazardous to place any faith in cost curves for equipment.

Installation Cost: Because of many variables, the installation cost cannot be estimated here with any degree of accuracy. Underground, there normally is rock in place to provide a base on which to pour a thin slab of concrete where the pump bedplate is anchored. The cost of such a foundation is nominal. The principal costs of installing an underground pump involve exca- vating the pump room, building the pump sump, installing the power lines and shaft column, and conveying power to the pump motors.

Power Cost: The cost of power is becoming increas- ingly important and the emphasis on pump and motor efficiency is growing. The cost of power may be calculated from the horsepower of the pump, the unit cost of power, and the number of hours the pump actually operates. The formulae are:

where C, is the power cost in dollars, Ckw,, is the cost per kilowatt-hour in dollars, P,, is the power consumption in kilowatts, T , is the pump-operation time in hours, Pbh, is the brake horsepower of the pump motor, and Em is the efficiency of the pump motor.

The utility company selling power to the mine should be contacted to obtain the charge per kilowatt-hour and an estimate of the increase in power rates over the next ten years.

Maintenance Cost: Assuming the pump is handling clean cold water, the maintenance cost may be estimated at $4/kW ($3 per hp) per year. Abrasive or corrosive materials in the mine water can increase this estimate considerably.

Installation When properly selected, installed, and maintained,

centrifugal pumps operate satisfactorily for a long period of time.

Location: The pump should be located so that the suction pipe can be short and direct with a minimum of fittings. If possible, the pump suction should have a positive head; Fig. 11 illustrates a piping arrangement with a positive head on the suction. Adequate space must be provided to inspect, remove, and repair units, and provisions should be made for lifting devices needed to handle heavy pieces such as the complete pump or the complete motor. Frequently, it is desirable to allow adequate space in the pump room for the installation of additional pumps at some future date.

GATE VALVE-, PET COCK \ /GATE VALVE

Fig. 11. Typical piping arrangement with a positive head on the suction.

Foundation: The foundation should form a rigid support for the pump's bedplate and should absorb mechanical vibration. A foundation must not be located on a fault or rock fracture that might move or shift and disturb the pump alignment.

The most satisfactory foundations are constructed of reinforced concrete. Elevation drawings obtained from the pump manufacturer identify the locations for the anchor bolts, the size of the bolts, and the dimensions for required grouting. In installing the foundation bolts, the threaded bolt length above the rough surface of the concrete should be somewhat longer than specified; any unused excess can be cut off later. When applying grout, a rough finish on the top of the concrete foundation is desirable. Fig. 12 illustrates a typical template for hanging foundation bolts while pouring the foundation. Fig. 13 illustrates the typical arrangement of the foundation bolt within the foundation.

Bedplate Leveling: The procedure to level the bedplate should include:

1 ) Disconnect the flexible coupling between the pump and the motor.

2) Prepare iron wedges or shims 102 to 152 mm (4 to 6 in.) long and 51 to 76 mm (2 to 3 in.) wide to go on each side of all foundation bolts. The wedges or shims should be thick enough to allow 19 to 38 mm (0.75 to 1.5 in.) of grout to be placed under the edge of the bedplate. Fig. 14 illustrates the method of placing the wedges or shims with a pinch bar.

3 ) Level the bedplate using a 229-mm (9-in.) machinist's level on the machined surface and snug down the foundation bolts. When the bolts have been tightened, recheck the level.

Alignment: It is extremely important that the pump and motor be aligned properly. A flexible coupling is not a universal joint. There will be some vertical ex- pansion when the pump is running under normal condi-

allow bolts to project for grouting under bed plate

make this distance equal to lug on bed plate

Fig. 12. Typical template for hanging foundation bolts while pouring a foundation for a pump.


allow ample threaded bolt length above rough concrete

rough finish stuff wastearound bolt while pouring

pipe sleeve to be three times diameter

' -. of anchor bolt

and pipe sleeve to

. . " 0 6 . C . . . . .

Fig. 13. Cross section of a concrete foundation showing the arrangement of a foundation bolt.

tions; the vertical difference between the pump and motor should be measured when the equipment is cold, and this difference should be recorded on a tag attached to the coupling. Generally, pumping a cold or cool liquid allows the motor to "grow" more than the pump; when the pump and motor both are cold, the motor coupling should be 0.13 to 0.20 mm (0.005 to 0.008 in.) lower than the pump-half coupling. Fig. 15 illustrates the steps necessary to align the coupling, and the alignment must be within 0.08 mm (0.003 in.) when the equipment is operating at normal temperature. The procedural steps shown in Fig. 15 are:

1 ) Measure the vertical angular misalignment; the coupling faces must be parallel to within 0.08 mm (0.003 in.).

2) Measure the horizontal angular misalignment; the coupling faces must be parallel to within 0.08 mm (0.003 in.).

3) Measure the vertical alignment; the coupling faces must be parallel to within 0.08 mm (0.003 in.).

4) Measure the horizontal alignment.

Fig. 15. Method of aligning the motor-to-pump coupling.

Grouting: Grouting is used to distribute the pump load uniformly over the foundation. Fig. 16 illustrates the method of placing the grout, and the procedure is:

1) Build a wood dam around the foundation as shown in Fig. 16. Since the leveling wedges may be removed after grouting, the locations of the wedges

,. . should be marked before pouring the grout. 2) Prepare the grout mixture. A good mixture

Fig. 14. Method of leveling a bedplate using wedges or consists of one part cement to two pads clean sharp shims and a pinch bar. sand. Enough water should be added so that the mixture

ANCl LLARY EQU l PMENT

Fig. 16. Cross section of foundation grouting, showing the position of the wood dam used when pouring grout.

flows evenly and is approximately the consistency of heavy cream; too much water allows the cement to separate out of the mixture.

3) Pour the grout to fill the area under the bedplate completely. Holes in the bedplate allow air to escape and serve as inspection ports.

4) After the grout has hardened completely, remove the wood dam and the leveling wedges. Use additional grout to fill the holes left by removing the wedges.

5) Pull down the foundation bolts, recheck the pump level, and recheck the pump and motor alignment.

Many grouting materials are available, but only some of them are usable in this application. The pro- posed use of any new material always should be checked with someone who has used it and whose opinions are reliable. Do not connect any piping until the grout has hardened thoroughly and the foundation bolts have been pulled down.

Pump Column: The pump column should be of a diameter sufficient for the water velocity to approximate 4.6 m/s (15 fps). Too small a diameter increases the power consumption, while too large a diameter can result in "water hammer" problems. A check valve and a gate valve should be installed in the discharge pipe; the check valve should be between the gate valve and the pump discharge flange. The check valve protects the pump and packing from excessive pressure surges and it prevents the pump from running backward. The gate valve allows the check valve to be inspected, and it may be used for priming and starting the pump.

Suction Pipe: The suction pipe should be short and direct. The horizontal section of the pipe should have a gradual rise so that no section of the horizontal line is above the pump's suction nozzle. If possible, a flooded suction should be provided. If a gate valve must be installed in the suction line, the valve should be mounted to position the valve stem in a horizontal or bottom direction, thus reducing the possibility of encountering air pockets or air leakage. The suction line should be large enough so that the water velocity does not exceed 2.4 m/s (8 fps). Fig. 17 illustrates correct and incorrect methods of installing suction and discharge pipes.

GATE CHECh ULM VALVE

CENTRCl REEKER

ffi RADIUS ELBOW

STRAINER

ECCENTRC SUCTION PPC SLOPES N WARD f ROM PU*P

RADIUS ELBOW

CORRECT

Fig. 17. Correct and incorrect methods of installing suction and discharge pipes for a mine pump.

Priming: Before starting a centrifugal pump, it is necessary to prime the system. If the pump has a flooded suction, there is no problem; a vent on the top of the pump casing should be opened to bleed all air out of the system. However, if the pump has a suction lift, one of two possible priming methods must be used:

1) The pump suction line may be equipped with a foot valve that is installed below the water level. The pump and suction line can be filled with water from some source such as a fresh-water line from the surface or water from the discharge of another pump. The proper location of the foot valve is shown in Fig. 17.

2) The pump may be provided with an aspirator (ejector) or a vacuum system to remove the air from


the pump casing and to "suck" water into the casing and suction pipe. When this method is used, a foot valve should not be used. This is the preferred method of priming a pump and a simple aspirator, operating on compressed air, can be assembled from standard pipe fittings. Or, a commercial ejector can be purchased. Fig. 18 illustrates the arrangement for priming with an ejector.

Startup Procedure If properly performed, the startup procedure can

prevent time-consuming and costly problems. Fre- quently, the personnel starting the new pump installation are not the same as those who installed the equipment. Therefore, the following steps should be taken:

1 ) The entire unit and surrounding area should be cleaned.

2) All main and auxiliary piping should be checked to make certain that the piping has been connected properly and is free of foreign objects such as rags, gloves, pieces of wood, welding slag, rocks, and lunch pails. It is prudent to install a conical strainer at the pump's suction flange before startup.

3) The pump and motor bearings should be cleaned and lubricated.

4) The level and alignment should be rechecked. 5) The motor's direction of rotation should be

checked before connecting the coupling. After being checked, the coupling should be assembled.

6 ) The discharge valve should be closed. 7) The pump should be primed, making certain

that all air is bled out of the casing and suction pipe. A pump that is run dry may "seize."

8) The water to the stuffing boxes should be turned on, and the pump unit started.

9 ) As soon as the pump reaches operating speed, the discharge valve should be opened slowly.

10) With the pump operating, the stuffing-box packing should be checked. When the pump is packed, the glands should not be drawn up very tightly, and there should be a considerable amount of leakage when the pump is started so that the packing stays cool and does not glaze. As the pump runs, the stuffing-box gland nuts may be tightened to reduce the leakage, but there always should be some leakage to lubricate the packing and cool the stuffing box.

CCCNTRIC REDUCER

ONG RADIUS ELBOW

Fig. 18. Typical arrangement for pump-system priming by means of an ejector.

11) After a few hours of operation, the pump and motor alignment should be rechecked.

12) After several hours of operation, the bearing temperature should be checked; this temperature should not exceed 71 "C (160°F).

13) The suction and discharge pressure gages should be checked. If the readings are not at or near the anticipated pressures, the unit should be shut down and the problem located and corrected.

14) After running for several days and completing a final check of the alignment, the unit should be doweled. Tapered dowel pins between 6.4 and 25.4 mm (0.25 and 1.0 in.) should be installed in diagonally opposite feet of the pump and motor. It is not necessary to dowel small- or medium-size single-stage pumps.

15) When the pump is subject to freezing tempera- tures while not in operation, the casing should be drained by removing the pipe plugs in the bottom of the casing.

Automatic Pump Control Automatic pump control frequently is installed and

pumps are checked only once a shift. The basic automatic control is a sensing device that starts and stops the pump as the level of the mine water in the suction sump fluctuates. That can be a simple float switch, or it can be an array of electronic probes. If the pump operates with a suction lift, it is important that a device be provided to make certain that the pump is primed properly before it starts. If clean water is scarce or expensive, automatic water valves can be installed on the stuffing box. Highly sophisticated sensing devices of various types also are available to further safeguard the pump and motor. In all cases, an alarm system should be provided to indicate when the water level in the sump rises above a predetermined limit.

Maintenance If the pump has been installed properly and if the

suction sump is adequate to allow abrasive solids to settle, the maintenance of a mine pump usually is quite simple.

Rotating Elements: For pumps that are vital to mine operations, at least one spare rotating element should be kept on hand, complete with all elements necessary for immediate installation. This includes a pump-half flexible coupling so that a damaged or worn rotating element can be removed and a new rotating element can be installed quickly. Some mines have a heavy welded steel box in which the spare element is placed, lowered into the mine, and stored in the pump room; the element is not removed from this box until it is installed directly into the pump. The rotating element must be handled with extreme care since the aligment of the element is critical to proper operation.

To assess the wear on internal pump parts, it is good practice to install an ammeter that registers the motor amperage. When the motor amperage falls below a predetermined lower limit, the pump rotor should be replaced-such a decrease in amperage indicates that the internal clearances have increased to a point where excessive internal water recirculation is occurring. This is particularly important on multi- stage pumps. The use of the ammeter eliminates the need for frequently opening the pump casing to inspect the internal parts; as long as a pump is functioning properly, it is advisable to avoid opening the casing.

ANCILLARY EQUIPMENT 1347

Lubrication: The ideal lubricant for ball bearings is a straight well-refined neutral mineral oil, preferably of a turbine type. For the majority of applications, SAE 10 motor oil meets the requirements. Table 2 summarizes some suggested oil specifications. It is good practice to change the oil in the bearing housings once every 600 hr of operation.

Record Card: For each pump, a record card or log book should be maintained conscientiously. Table 3 lists the contents of a suggested record card; this information greatly assists in diagnosing any problem that might develop.

Operating Difficulties: Some 85% of the troubles encountered with centrifugal pumps occur on the suction side. The possible problems may be classified into four groups: no water or insufficient water delivered, insufficient pressure, intermittent operation, and excessive power consumption.

No Water or Insufficient Water Delivered-Prob- lems indicated by no water or insufficient water delivered may be caused by: improper priming with the pump casing not full of water, too low an operating speed, too high a discharge head, too high a suction lift, a plugged impeller passage, an incorrect direction of rotation, air leakage into the suction pipe or stuffing boxes, an insufficiently submerged suction-pipe entrance, mechanical defects or worn internal clearances, or too small an impeller diameter.

Insufficient Pressure-Problems indicated by insufficient pressure may be caused by: too low an operating speed, mine water containing excessive entrained air or gas, too small an impeller diameter, or a total head higher than that calculated.

Intermittent Operation-Problems indicated by intermittent operation, with the pump operating for a while and then stopping, may be caused by: air leakage into the suction line or stuffing boxes with a subsequent loss of priming, an improperly functioning water seal, mine water containing excessive entrained air or gas, or too high a suction lift.

Excessive Power Consumption-Problems indicated by excessive power consumption may be caused by: a total head lower than that calculated; too high an operating speed; mechanical defects such as a binding rotor, a misaligned pump, or an excessively tight stuffing box; or electrical defects such as low voltage or fre- quency that cause motor overheating.

MINE-DEWATERING PUMPS

Most mine-dewatering pumps are of a vertical design. They may be hung in a shaft to follow the water level down, or they may be installed as submerged pumps in a shafts or boreholes that intersect the mine workings. When dewatering a mine, the pumped water is usually free of solids because the water has been standing (and settling) for an appreciable period of

time. If a standard vertical pump is installed in the shaft of a flooded mine, it can be mounted on a crosshead on the old shaft guides and lowered as the water recedes. The discharge is connected to the pump column by rubber hose or, in some instances, a tele- scopic pipe arrangement that allows the lower length of pipe to slide out the lower end of the pump column through a packed stuffing box. Another method of mounting the pump is to secure it to a float or raft that follows the level of the water as the pumping progresses.

Selection of Pumping Equipment The selection of the proper size pump for dewater-

ing a mine requires a calculation of the volume of the flooded mine workings plus estimated water inflow, and the total head against which water must be pumped. Since the total head varies as the water rece s, selection 4e of the pump frequently depends upon the qtent of the head variation. In some cases, it is desirable to select a multi-stage pump capable of pumping against the maximum head which will be encountered; when the pump is operating against a lesser head, at the start, remove several stages of impellers, replacing them with spacers.

In another approach, the dewatering pumps are staged. An initial pump Lowers the water to a predetermined level, a permanent pump is installed on that level, and the initial pump then lowers the water to the next predetermined level. This method allows a permanent pump to be installed on each level as it is reached. Frequently, these pumps are horizontal split- case designs which may be more economical than the vertical dewatering pumps.

It is not practical to propose a specific pump arrangement; the best arrangement usually depends upon many different factors that vary from mine to mine. Some of these factors include: the quantity of water to be pumped, the time available for the dewatering operation, the depth of the shaft to be dewatered, the depth at which the major water volume is located, the available power supplies, the physical conditions of the mine and shaft, and the purpose of the dewatering operation.

When dewatering a mine, a formal provision must be made for disposition of the pumped water. The lack of proper arrangements has delayed a number of mine dewatering projects and has resulted in legal problems. In arid country, allowing even clean mine water to flow onto a rancher's property can result in trouble- particularly if the rancher sees an opportunity to profit from litigation. On occasion, it may be possible to make a deal with such an individual prior to com- mencing the dewatering operation, allowing that individual to buy the water for some nominal amount, but making him feel that he outsmarted the mining company.

Table 2. Recommended Speclflcations for Bearing Lubricants

Item Napthene Base Paraffin Base -

Flash Point 166°C (330°F) min 182°C (360°F) rnin Saybolt Viscosity, 38°C (100°F) 150 sec min 140 sec min

200 sec rnax 185 sec max Pour Point - 15°C (5°F) max 2°C 135°F) rnax


Driver - Motor Manufacturer - GE Serial No.-123870 Type -OPEN

Table 3. Typical Record Card Contents tor Pump Maintenance

-

H. P. - 40 RPM - 2900 Frame - 404 Enclosure - Tri-Clad

Serial No. 01 43 783

Volts - 440 Phase - 3 Cycles - 50

Inlet Steam, psi. ga. - Total Temp. "F - Exhaust, psi. ga. -

Control: Type - CR-7051 Manufacturer - GE

Size & Type 3GF

Rated Condltlons: Gpm . . .360 . . . . . . . . . .

. Total head, feet .320.. Suction ++or - feet. -5. Rpm . . . ,2900 . . . . . . . .

. . . . . . Liquid . . . . water Temp. O F . . . .72". . . . . . . Viscosity . . . .97 cent . . .

. . . . . . . . . . Sp. gr. . . .l.O Impeller Pattern 3GT3H-R

. . . . . Dia 8-114 In.

Costs of Dewatering

Pump Mfr. Ingersoll-Rand

INSPECTION 8 REPAIRS

The costs of a dewatering operation are dependent upon many local factors, making it impractical to attempt a definition of dollar costs. Instead, it is helpful to describe the various items that affect the costs.

Fist Cost: The first cost can be calculated only after the contributing factors previously listed have been determined. An important consideration in evaluating the first cost is to establish the source of power necessary to operate the pumps. If the mine has been shut down for an appreciable length of time, the power lines and electrical distribution system often have deteriorated to a point where a major expense is in- volved in reestablishing power supplies.

7-7/16 . . . . . . 1 Ring Clearance 004"

Stuff. Box Dlmonslons: O.D. 2-7/8 . . I.D. 1-911 6 Packing Size 318 In. Sq.

No. of Rings 1-6, 2-6. . Packing Mfr.. 5-R-N.. .

. . . . . Packing No. 505.

Date:

6/29/43

Power Cost: The cost for the power needed to dewater a flooded mine is a function of the water volume, the pumping height, and the volume of ground water that continues to flow into the mine as the residual water is removed. For most purposes, the water inflow may be assumed to equal the inflow ex- perienced prior to the mine being flooded.

Cost Determinations: To estimate the cost of pumping the residual water from the flooded mine, a map of the mine workings may be used to calculate the volume and the average head. To facilitate the calculation, arbitrarily divide the workings into logical units, calculating the volume of water and an estimated average lift for each unit. Then integrate the individual

Mfr. Order No. 01-54 Item No. 2A Cust. Order No. 431

Pump Materlrls: Casing . . . CI . . . . . . . . Casing Rings. . Br . . . . Impeller.. Br . . . . . . . . Imp. Rings. . Br . . . . . . Shafi . . . st . . . . . . . . . . Shafi Sleeves.. Ph-Br Radial Brg. Type-Ball . .

Size 1307 Thrust Brg. Type-Ball

Size 74-05-0 . . . . . . . Casing Gasket

Thickness 1/32" Normal Wearing.. . . . .

Date Shipped 1-29-43

Condition:

Good

Due to:

Reg-Inspect

Repaired by:

G WM

Cost:

- Remarks:

-

ANCILLARY EQUIPMENT

Table 5. Typical Submergences for Alr-Llft Pumps

Customary Allowable Lift, m (ft) Submergence, % Best Submergence, %

and a high-capacity, low-lift jet. In either case, water forced under pressure down the passage at the right enters the Venturi throat at high velocity and draws water from below. The two streams merge in the gradually widening Venturi and they are propelled up- ward into a discharge pipe.

Fig. 26 illustrates the use of a jet pump for draining a sump. In this case, a motor pump (centrifugal) used for dewatering the sump may provide the high-pressure water to operate a jet pump at a lower level.

Fig. 27 illustrates the use of a jet pump for draining a passageway. The jet is stationed in a low spot and is equipped with a float-operated valve. The operating water is obtained from a pressure line or from a centrifugal pump.

HYDRALlLlC MINING

Modern underground hydraulic mining in the United States began in 1948 with the mining of gilsonite by the American Gilsonite Co. near Salt Lake City, UT.

Table 6. Dimensions and Rated Capacltles for VA System Alr-Lift Pumps

Pipe Rated Capacity. Us (gpm) Dimensions Smallest Connections

Diam. Submergence, % Overall Size of Well Discharge, Air, 0 D, Length, Weight, No. mm (in.) mm (in.) mm (in.) 70 60 50 40 mm (in.) m (ft) kg (Ib)

Wlth Stralght Dlscharge Plpe 1 102 (4) 38 (1.5) 13 (1.5) 0.9-1.5 0.8-1.3 0.8-1.1 0.6-1.0 89 (3.5) 1.96 (6.44) 24 (54)

(1 5-24) (1 3-20) (1 2-1 8) (1 0-1 6) 2 127 (5) 51 (2.0) 19 (0.75) 1.5-2.5 1.5-2.3 1.3-2.2 1 .l-1.9 108 (4.25) 1.99 (6.52) 31 (69)

(25-40) (23-37) (20-35) (1 7-30) 3 152 (6) 64 (2.5) 25 (1 .O) 2.5-4.1 2.3-3.8 1.9-3.5 1.7-3.2 130 (5.125) 2.01 (6.58) 40 (88)

(40-65) (37-60) (30-55) (27-50) 4 152 (6) 76 (3.0) 25 (1 .O) 4.4-6.6 4.1-6.3 3.8-6.3 3.5-6.0 140 (5.5) 2.04 (6.69) 48 (106)

(70-1 05) (65-1 00) (60-1 00) (55-95) 5 152 (6) 89 (3.5) 25 (1 .O) 7.3-9.5 6.6-8.5 6.3-8.2 6.0-7.6 149 (5.875) 2.05 (6.74) 50 (1 10)

(1 15-1 50) (1 05-1 35) (1 00-1 30) (95-1 20) 6 203 (8) 102 (4.0) 32 (1.25) 9.5-12 8.5-1 1 8.2-10 7.6-9.5 187 (7.375) 2.07 (6.79) 66 (146)

(1 50-1 90) (1 35-1 70) (1 30-1 60) (1 20-1 50) 7 203 (8) 114 (4.5) 38 (1.5) 12-14 11-14 10-13 9.5-12 200 (7.875) 2.09 (6.85) 77 (169)

(1 90-240) (1 70-220) (1 60-200) (1 50-1 90) 8 254 (10) 127 (5.0) 38 (1.5) 15-22 14-20 13-1 8 12-1 7 222 (8.75) 2.1 1 (6.91) 97 (213)

(240-350) (220-320) (200-290) (1 90-275) 9 254 (1 0) 152 (6.0) 38 (1.5) 24-35 22-32 20-29 19-28 248 (9.75) 2.1 1 (6.94) 11 5 (254)

(380-560) (350-51 0) (320-460) (300-440)

Wlth Tapered Dlwharge Plpes 1 102 (4) 38 (1.5) 13 (0.5) 1.2-2.Q 1.1 -1.8 1 .O-1.6 0.9-1.3 89 (3.5) 1.96 (6.44) 24 (54)

(1 9-32) (1 8-29) (1 6-26) (1 4-20) 2 127 (5) 51 (2.0) 19 (0.75) 2.1-3.6 1.9-3.2 1.8-2.7 1.6-2.5 108 (4.25) 1.98 (6.5) 31 (69)

(34-57) (30-50) (28-43) (26-39) 3 152 (6) 64 (2.5) 25 (1 .O) 3.3-5.6 3.1-4.9 2.8-4.2 2.5-3.8 130 (5.125) 2.01 (6.58) 40 (88)

(53-88) (49-77) (44-66) (40-61 ) 4 152 (6) 76 (3.0) 25 (1.0) 6.1-9.7 5.4-8.5 4.9-7.3 4.4-6.4 140 (5.5) 2.04 (6.69) 48 (106)

(97-1 54) (85-1 35) (77-1 15) (69-1 02) 5 152 (6) 89 (3.5) 25 (1 .O) 8.4-14 7.7-12 6.9-1 1 6.3-9.7 149 (5.875) 2.05 (6.74) 50 (1 10)

(133-222) (1 22-1 95) (1 10-1 67) (1 00-1 53) 6 203 (8) 102 (4.0) 32 (1.25) 12-1 9 10-17 9.5-15 8.5-13 187 (7.375) 20.7 (6.79) 66 (146)

(1 90-305) (1 65-270) (1 50-230) (1 35-21 0) 7 203 (8) 114 (4.5) 38 (1.5) 15-25 14-22 13-1 9 11 -1 7 200 (7.875) 2.09 (6.85) 77 (1 69)

(240-400) (220-350) (200-300) (1 80-275) 8 254 (10) 127 (5.0) 38 (1.5) 20-33 18-29 16-25 15-22 222 (8.75) 2.1 1 (6.91 ) 97 (213)

(31 0-520) (285-455) (260-390) (235-355) 9 254 (1 0) 152 (6.0) 38 (1.5) 32-53 29-46 26-40 24-37 248 (9.75) 2.1 1 (6.94) 11 5 (254)

(505-840) (460-735) (420-630) (380-580)

UNDERGROUND MlNl'NG METHODS HANDBOOK

Table 7. Dimensions and Rated Capacities for VC System Airlift Pumps

Pipe Rated Capacity, Us (gpm) Smallest Connections

Diam Submergence, % Size of Well Discharge, Air*, Weight, No. mrn (in.) mrn (ih.) mm (in.) 70 60 50 40 kg (Ib)

W#h Straight Discharge Pipe 1 102 (4.0) 51 (2.0) 13 (0.5) 1.3-2.1 1.2-1 .O 1.1-1.8 0.9-1.6 26 (58)

(21 -34) (19-31) (1 7-29) (1 4-25) 2 114 (4.5) 64 (2.5) 19 (0.75) 2.1-3.3 1.9-3.1 1.6-2.8 1.4-2.6 34 (76)

(33-53) (30-49) (25-45) (22-41 ) 3 127 (5.0) 76 (3.0) 25 (1.0) 3.6-5.4 3.3-5.0 3.1-4.1 2.8-4.1

(57-86) (53-80) (49-65) (45-65) 43 (94)

4 140 (5.5) 89 (3.5) 25 (1 .O) 6.3-8.2 5.7-7.4 5.4-7.1 5.2-6.3 49 (1 08) (1 00-1 30) (91-117) (86-1 12) (83-1 00)

5 152 (6.0) 102 (4.0) 32 (1.25) 7.8-10 7.1 -8.9 6.8-8.4 6.3-7.9 57 (125) (1 24-1 58) (112-141) (1 08-133) (1 00-1 25)

6 178 (7.0) 114 (4.5) 38 (1.5) 9.8-13 8.8-1 1 8.3-1 0 7.8-9.8 67 (1 48) (1 56-200) (140-1 81) (1 31 -1 65) (1 23-1 56)

7 203 (8.0) 127 (5.0) 38 (1.5) 13-19 12-1 7 11-15 10-1 5 85 (1 87) (206-300) (1 90-275) (1 72-230) (1 64-235)

8 229 (9.0) 152 (6.0) 38 (1.5) 21-30 19-28 17-25 17-24 102 (225) (330-480) (300-440) (275-400) (265-380)

9 254 (10.0) 178 (7.0) 51 (2.0) 30-44 27-40 25-36 24-34 11 1 (245) (470-690) (435-630) (390-575) (375-540)

10 279 (1 1 .O) 203 (8.0) 51 (2.0) 40-59 37-54 33-49 32-47 151 (334) (640-930) (590-850) (530-775) (510-740)

1 1 330 (1 3.0) 254 (1 0.0) 64 (2.5) 73-106 67-97 61 -88 58-82 212 (467) (1 150-1 680) (1 060-1 530) (960-1 400) (920-1 300)

Wlth Tapered Discharge Plpes 1 102 (4.0) 51 (2.0) 13 (0.5) 1.4-2.4 1 .O-2.0 0.8-2.3 0.7-2.1 26 (58)

(22-38) (16-31 ) (1 3-36) (1 1-33) 2 114 (4.5) 64 (2.5) 19 (0.75) 2.1 -3.6 1.5-3.2 1.3-3.0 1 .O-2.6 34 (76)

(33-57) (23-51 ) (20-48) (1 6-42) 3 127 (5.0) 76 (3.0) 25 (1 .O) 3.6-6.1 2.5-5.6 2.1-5.4 1.8-4.4 43 (94)

(57-97) (40-88) (34-85) (28-70) 4 140 (5.5) 89 (3.5) 25 (1.0) 5.0-8.8 3.7-7.9 3.2-6.6 2.5-6.6 49 (108)

(80-1 40) (58-1 25) (50-1 05) (40-1 05) 5 152 (6.0) 102 (4.0) 32 (1.25) 8.8-15 6.3-13 5.4-1 1 4.4-8.8 57 (125)

(1 40-240) (100-210) (86-1 72) (70-1 40) 6 178 (7.0) 114 (7.5) 38 (1.5) 13-21 8.8-18 7.6-1 5 6.3-13 67 (148)

(200-340) (1 40-280) (1 20-240) (1 00-200) 7 203 (8.0) 127 (5.0) 38 (1.5) 20-34 14-28 12-24 10-20 85 (187)

(320-540) (225-450) (1 90-380) (1 60-320) 8 229 (9.0) 152 (6.0) 38 (1.5) 29-49 20-40 17-34 15-29 102 (225)

(460-780) (320-640) (275-540) (230-460) 9 254 (10.0) 178 (7.0) 51 (2.0) 39-66 27-55 23-47 20-39 11 1 (245)

(620-1 050) (430-865) (370-740) (31 0-620) 10 279 (1 1.0) 203 (8.0) 51 (2.0) 53-88 37-74 32-63 26-53 151 (334)

(840-1 400) (585-1 1 75) (500-1 000) (420-840) 11 330 (1 3.0) 254 (10.0) 64 (2.5) 88-148 62-1 24 53-1 06 44-88 212 (467)

(1 400-2350) (975-1 960) (840-1 675) (700-1 400)

* In the well, use the smallest diameter air line possible without producing excessive friction.

In mining gilsonite, a 6.4-mm (0.25-in.) water jet having a pressure drop of 15 860 kPa (2300 psi) across the nozzle will cut 23 to 27 t /hr (25 to 30 stph). The 6.4-mm (0.25-in.) nozzle will pass approximately 6 L / s (100 gpm) of water. Approximately 22 L/s (350 gpm) of low-pressure water is used to flume the ore to a receiving pocket where it is sized and crushed to 19 mm (0.75 in.) and then pumped 244 m (800 ft) vertically to the slurry preparation plant on the surface. On the surface, a 40% slurry is pumped through 116 km (72 miles) of pipe to the refinery.

Interest in the use of hydraulic techniques for coal mining began in the United States in 1958. However,

the Soviet Union had reported success in hydraulically mining and transporting coal as early as 1936. A greater emphasis was placed on developing coal-mining techniques in the Soviet Union, Japan, and European countries because those countries relied heavily upon coal, while the United States relied heavily on cheap oil and gas.

Since 1971, Kaiser Resources, Ltd., Sparwood, BC, has been operating a successful hydraulic coal mining and transport system, using Soviet and Japanese methods and equipment. The "hydraulic monitor" used in that operation breaks coal at a rate of 4 to 9 t/min (5 to 10 st per min).

ANCILLARY EQUIPMENT

Fig. 23. Typical two- stage combination jet pump with a first-stage jet and a second-stage

centrifugal.

In the Kaiser Resources' operation, the main high- pressure pump is located on the surface. This is a seven-stage pump that is driven by a 1860-kW (2500- hp) motor and delivers 95 L/s (1500 gpm) at 13 790 kPa (2000 psi). The high-pressure water is carried underground through a 203-mm (8-in.) pipeline to the sublevels, and the water is delivered to the monitor through a 152-mm (6-in.) pipeline. The monitor is fitted with either a 23.0-mm (0.91-in.) diam nozzle or a 28.3-mm (1.1 1-in.) diam nozzle. The nozzle selection depends upon the hardness of the coal in the area being mined. The pressure drop across the nozzle is approximately 11 030 kPa (1600 psi). The monitor is controlled from a remote-control console positioned 11 m (35 ft) downslope from the monitor. The monitor is positioned by two hydraulic cylinders, with one for the swing and the other for the dump. The hydraulic cylinders are actuated by 2760 kPa (400 psi) of water

pressure obtained through a reducing valve from the monitor's 1 1 030-kPa ( 1600-psi) supply line. This monitor can break coal at a distance of up to 21 m (70 ft) from the nozzle.

Assisted by a small remote-controlled auxiliary monitor with a 12.0-mm (0.47-in.) nozzle, the broken coal is sluiced to a breaker that reduces the coal to approximately -152 mm (-6 in.). The breaker is located downslope from the monitor, but upslope from the control console. Behind the breaker, the coal and water enter a steel flume that carries the coal down the sublevel and into the mainline roadway flume that leads to the treatment plant on the surface. This has proven to be an efficient method of mining thick coal seams with a steep dip.

Hydraulic mining systems also are being developed for use in some of the uranium mines in the western United States. Where deposits of uranium ore are con-

LlNDERGROLlND MINING METHODS HANDBOOK

Fig. 24. Comparative operating characteristics of typical low- and high-lift jet pumps. Metric equivalents: f t X 0.3048=m; gpm X 0.063 090 2 =

L/ s.

LOW-LIFT JET 26W HIGH- LIFT JET

240-

220-

P 20

PUMPED CAPACITY IN GALLONS PER MINUTE

LOW CAPACITY HIGH CAPACITY HGH LIFT LOW LIFT

Fig. 25. Comparative jet constructions of a low-capacity high-lift jet (left) and a high-capacity low-lift jet (right).

Metric equivalent: gal = 3.785412 L.

Fig. 26. Method of using a jet pump for draining a sump.

ANCILLARY EQUl PMENT

P i s c h a r g e Line -

- Jet

Fig. 27. Method of using a jet pump for draining a mine passageway.

tained in loosely consolidated sandstone, some mining has been done through a borehole with a high-pressure water jet that knocks down and sluices the uranium- bearing sandstone to a vertical submersible pump. The slurry then is pumped to the surface. This technique still is undergoing development-mechanical maintenance problems have been quite persistent as a result of the abrasive nature of the sandstone.

HYDRAULIC HOISTING

Under certain conditions, hydraulic hoisting of ore has proven to be practical. This method is particularly applicable when a large quantity of water must be pumped to keep a mine dry, or when a hoisting shaft is operating at full capacity while additional ore must be hauled without sufficient justification for the installation of a new mechanical hoisting system.

Several important hydraulic hoisting installations are working satisfactorily. At the Devillaine coal mine near St. Etienne, France, a demonstration hydraulic hoist was installed in 1960. It hoisted 45 to 54 t /h (50 to 60 stph) of -82.6 mm (-3.25 in.) coal up a 180-m (590-ft) shaft and through a 76-m (250-ft) horizontal pipeline to the treatment plant. That lift required a total of 48.5 kW (65 hp), of which 12.7 kW (17 hp) was used for the horizontal transport.

In Czechoslovakia's Kutna Hra district, lead-zinc ore is lifted 460 m (1500 ft) with an hydraulic system. At the Lengede Broistedt iron-ore mine in West Ger- many, the conventional mechanical hoisting system has been replaced by an hydraulic system that handles up to 4540 t /d (5000 stpd) from a depth of 120 m (395 ft).

One of the most interesting hydraulic hoist installations is at Anglo-American Corp.'s Vaal Reefs gold mine near Klerksdorp, South Africa. This system is pumping gold-bearing quartzite from the 2190-m (7200-ft) level to the surface. Using MarsT" reciprocating pumps, 22 700 t [(25,000 st) dry tonnage] are pumped per month through four lifts. The installation of an hydraulic hoisting system was prompted by the fact that the shaft already was operating at its maximum capacity of 136 000 t (150,000 st) per month, and it was necessary to hoist additional ore.

In the South African operation, the run-of-mine ore is screened. The -6.4 mm (-0.25 in.) material is passed through a ball mill in which it is reduced to a sludge consisting of -65 to +200 mesh material (80% ) and -200 mesh material (20%). The oversize ore goes from the screening operation to the conventional hoist. In the past, the fines in the ore caused delay problems in conventional hoisting as a result of the sticky nature of the ore; removing the fines from the conventional hoisting system has increased its hoisting capacity.

PUMP INFORMATION SUMMARY Table 8 summarizes the pump-system parameters

and features for various mines operating in the United States. The table includes references to numbered notes that are as follows:

Note 1 Information concerning the AMAX operations at

Climax, CO, was obtained from Al Smith, chief engineer. Information on the Henderson mine was obtained from D. E. Julin, chief engineer. Information on AMAX Lead Co.'s Buick mine in Missouri was obtained from AMAX Lead Co. of Missouri and Home- stake Lead Co. For the Buick mine, the pumping cost, including power and maintenance, is $0.62 per 100 L/s ($0.39 per 1000 gpm). The approximate cost of the pumps at the time of purchase in 1968 was $20,800 each, including the pump, motor, and starter.

Note 2 At Anaconda Co.'s Butte mines, underground water

from the surrounding mines is collected in the Kelley mine. The collected water is pumped to the surface from pump stations located on the 4000 level [elevation = 664 m (2177 ft)] and the 3900 level [elevation = 710 m (2328 ft)] of the Kelley mine. The elevation at the collar of the Kelley mine shaft is 1820 m (5970 ft) above sea level, and the elevation at the bottom of the shaft is 353 m (1 159 ft) above sea level. At present (19781, the Butte mines are flooded to the 4000 level.

Approximately 290 L/s (4600 gpm) of mine water is produced underground at the Butte mines, and this amount must be pumped to the surface. As of 1978,

1356 UNDERGROUND MlNllVG METHODS HANDBOOK

Table 8. Pump Information Summary

AMAX Lead Co., Anaconda, Anaconda, AMAX Mining Co., AMAX Mining Co., Buick Mine, Kellog Mine, Kelley Mine,

Item Climax, CO Henderson, CO Boss, MO Butte, MT Butte, MT

Depth of Shaft, 192 946 396 1466 1466 In ( f t ) (629) (3 1 03) (1 300) (481 1 ) (481 1)

Total water pumped, 378 158-1 70 215 145 290 Us (gpm) (2500-2700) (3400) (2300) (4600)

Pump level interval, 192 183 and 707 Single Level 55 1170 In ( f t ) (629) (600 and 2350) (180) (3840)

No. pumps on each 3 4 10 4 8 level

Capacity, each 189 126 69 158 63 pump, Us (gpm) (3000) (2000) (I loo) (2500) (1 000)

Total head, each 199 762 396 84 1250 Pump, m (ft) (654) (2500) (1 300) (275) (4100)

Motor power, each 447 1305 373 224 1119 pump, kW (hp) (600) (1 750) (373) (224) (11 19)

Motor current, 60 440 v 4160 v 4160 v, 2300 v, 41 60 v. Hz, 3-phase 61 amp 67.5 amp 176 amp

Pump control Automatic Automatic Automatic, Automatic, Manual, B 8. W probes probes Remote

Year installed 1971 1968 1978 1967 Pump manufacturer Wx 6-J Peerless 6-H Ingersoll-Rand Motor manufacturer Reliance Westinghouse' Reliance Westing house Suction lif t or Flooded Flooded Flooded Flooded

flooded Pump type Vertical Horizontal Vertical Horizontal Horizontal Sump retention time 75 min 2 hr 2 h r 21 h r 26 h r Pump column, diam 305 (12) [two] 254 (10) [three] 254 (10) [two] 254 (10) [four]

[mm (in.)] and schedule 80 steel 316 stainless 316 stainless material steel steel

Casing material Iron Carbon steel Carbon steel 31 6 stainless 105 stainless steel steel

Impeller material Bronze Hardened steel Bronze 316 stainless 105 stainless steel steel

Wear-ring material Bronze Bronze Stainless steel 316 stainless 385H stainless steel steel

Notest 1 1 1 2 2 - - - - --

* Information either not provided or not applicable. t See text for meaning of notes. 'Barrett Haentjens and Co.

145 L/s (2300 gpm) are pumped from the 4000-level pumping station and the remaining 145 L/s (2300 gpm) flow by gravity through a drain tunnel to the 3900-level pumping station. The 145 L/s (2300 gpm) pumped from the 4000 level goes to a drain tunnel above, where it joins the mine water at that level. The total mine water [290 L/s (4600 gprn)] flows through two vertical settlers that remove silt and into two pump sumps located at the 3900-level pumping station. From those sumps, the water is pumped to the surface through four 250-mm ( 10-in. ) ID 3 16 stainless-steel pipe columns. At the surface level of the shaft, each pipe column connects to a 305-mm (12-in.) mild-steel pipe that is lined with polyvinyl chloride (ParalineT" RD coating applied by Barber Webb Co.). These four lines extend for an additional 930 m (3050 ft) to a final elevation of 1880 m (6168 ft) above sea level before discharging into a wooden flume. From the flume, the mine water flows by gravity through two 406-mm (16-in.) Para- lineT'-lined steel pipes to a rubber-lined steel tank that measures 4.9 m (16 ft) high and 12 rn (40 ft) diam. This tank serves as a sump and a control tank for the surface pumping station. From the tank, the water is pumped to a mixing tank at the tailings pond [eleva-

tion = 1890 m (6200 ft)] where the mine water is mixed with concentrator tailings and additional milk of lime. The tailings, salts, and other solids settle out in the pond, and the water is reused in the copper concentrator. The estimated cost of pumping mine water for all three pumping stations is $1220 per 100 L/s per day ($770 per 1000 gprn per day).

Both underground pumping stations have been provided with additional pumping capacity to accommodate underground sloughs, which can occur and trap mine water. When the water finally breaks through, additional pumping capacity is required to prevent the pumping stations from being flooded. The temperature of the underground mine water averages 29.4"C (89°F) and the water is extremely corrosive. The water carries cupric and ferric sulfates and basic iron sulfate in solution, and it has a pH of approximately 4. Sulfuric acid is added to bring the acidity close to a pH of 2, thus holding the materials in solution and preventing deposition on the pipe walls. All pumps, pipelines, and other components that comc into contact with the mine water must be constructed of materials capable of withstand- ing the corrosive action.

According to Anaconda, the pumps working against

ANCILLARY EQUIPMENT 1357

Table 8. Pump Information Summary+continued)

Anaconda, Kelley Mine, Butte, MT

Homestake Homestake Gulf Resources Mining Co., Mining Co.,

and Chemical Co., Ross Shaft, Winze No. 6, Bunker Hill, ID Lead. SD Lead, SD

Homestake Mining Go.. Winze No. 4,

Lead. SD

Depth of Shaft, m (ft)

Total water pumped, Us (gpm)

Pump level interval, m (ft)

No. pumps on each level

Capacity, each Pump, Us (gpm)

Total head, each pump, m (ft)

Motor power, each Pump, kW (hp)

Motor current, 60 Hz, 3-phase

Pump control

Year installed Pump manufacturer Motor manufacturer Suction lift or

flooded pump type Sump retention time Pump column, diam

[mm (in.)] and material

Casing material

Impeller material

Wear-ring material

Surface

290 (4600) 12 (40) 3

158 (2500) 76 (250) 224 (300) 2300 v, 67.5 amp Automatic, probes 1973 B-H Reliance Flooded

Horizontal 20 min 406 (16) [one] pipeline

316 stainless steel 316 stainless steel 316 stainless steel 2

Automatic, probes

Ingersoll-Rand General Electric Flooded

Horizontal 10 hr

schedule 40 + 80 steel Cast iron and stainless steel Stainless steel

Stainless steel

Automatic

1975-1 978 Ingersoll-Rand General Electric Flooded and suction lift Horizontal 3-90 hr 305 (12) [one] schedule 40A53 steel Cast iron

Bronze

Stellite on 410

3

1036 (3400) 35 (550) 549 and 336 (1 800 and 1200) 2

44 and 32 (700 and 500) 556 and 390 (1 825 and 1280) 336 and 186 (450 and 250) 2300 v

Automatic

1973and 1976 Ingersoll-Rand General Electric Flooded

Horizontal 6 and 1 hr 305 (12) [one] schedule 40A53 steel Cast iron

Bronze

Cast iron

3

61 0 (2000) 32 (500) 366 and 183 (1200 and 600) 2-3

32 (500) 390 and 198 (1280 and 650) 186 and 93 (250 and 125) 2300 v

Automatic

1961 and 1966 Ingersoll-Rand General Electric Flooded

Horizontal 6 and 24 hr 305 (1 2) [one]

Cast iron

Bronze

Cast iron

3

' Information either not provided or not applicable. t See text for meaning of notes.

an 84-m (275-ft) head cost (in 1971) approximately $8000 each, the motor cost $3530, and the motor control center for all of the pumps cost $37,500. The pumps working against a 1250-m (4100-ft) head cost (in 1961) approximately $52,000 each, the motors cost $18,000 each, and the motor control center for all of the pumps cost $101,000. The pumps mounted on the surface and working against a total head of 76 m (250 ft) cost (in 1971) approximately $8000 each, the motors cost $3530 each, and the motor-starting equipment was available from another project and was supplied at no cost.

Note 3 Homestake Mining Co. estimates that the cost of

pumping water at Homestake is $0.42 per 1000 L ($1.60 per 1000 gal). This includes power, labor, and mechanical maintenance, but it excludes equipment depreciation.

At the time of purchase, pumping equipment for the Ross shaft cost approximately $56,000 for each unit, including the pump motor and the starting gear. The total cost of the pump installation at the Ross shaft is estimated to be $210,000, including equipment, installa-

tion cost, pump-room excavation, electric cables and transformers, and the pump column.

For winze No. 6, the original purchase cost of the pumps, motors, and starters was $1800 for the 335-kW (450-hp) units purchased in 1973 and $24,000 each for the 186-kW (250-hp) units purchased in 1976. The total cost of the pump installation, including the equipment, installation costs, pump-room excavation, electric cables and transformers, and pump column was $140,- 000 for the 335-kW (450-hp) units and $70,000 for the 186-kW (250-hp) units.

For winze No. 4, the pumps, motors, and starters had purchase costs of $1 1,000 for the 186-kW (250- hp) unit and $8000 for the 93-kW (125-hp) unit. The total costs of pump installation, including equipment, installation cost, pump-room excavation, electric cable and transformers, and pump column, were $60,000 for the 186-kW (250-hp) installation and $90,000 for the 93-kW ( 125-hp) installation. The 186-kW (250-hp) system was installed in 1961, and the 93-kW (125-hp) system was installed in 1966.

Information on Homestake Mining Co.'s pump in-


Table 8. Pump lntormatlon Summary+contlnued)

Homestake Pathfinder St. Joe Minerals St. Joe Minerals Mining Co., Mines Corp. Pilot Knob Corp., Virburnum Corp., Virburnum

Bulldog Mine, Lucky Mc Mine, Pellet Co., No. 28, No. 29, Item Creede. CO Riverton, WY Ironton. MO Bonne Terre. MO Bonne Terre. MO

Depth of Shaft, m (ft)




Capacity, each pump, Us (gpm)



140 (460) 63 (1 000) 122 (400) 6

17-20 (275-31 5) 122 (4oo) 37 and 45 (50 and 60)

3 or less (50 or less)

3 electric 1 air 6 and 3 (1 00 and 50) 23 (75) 19 and 7 (25 and 10)

25 and 69 (400 and 1 100) 91, 152, 366 (300, 500, 1200) 75 and 298 (100 and 400)

50 and 32 (800 and 500) 293 (960) 186 [7] and 93 [21 (250 and 125) 440 v Motor current, 60 480 v 440 v

Hz, 3-phase Pump control Automatic Manual Automatic,

probe 1975 and 1967 Ingersoll-Rand, B-H, Peerless General Electric 0.6-m (2.04) lift Horizontal 48 hr 254 (1 0) [one] schedule 60 steel Carbon steel Stainless steel

Automatic [21 and manual 171 1959-1 965 Peerless

Manual

Year installed 1971 and 1977 1976 and 1977 Pump manufacturer Ingersoll-Rand Flygt and

Warren Rupp Motor manufacturer ' Flygt Suction li f t or Flooded

flooded Pump type Horizontal Submersible Sump retention time 72 h r Pump column, diam 305 (12) [one]


Casing material Cast iron Steel Impeller material Bronze Alloy,

60 Rockwell C Wear-ring material Bronze Notest 3 4

1964 Peerless

US Motors Flooded

US Motors Flooded

Vertical 100 h r 254 (1 0) [one] steel

Vertical 50 h r 254 (10) [one] steel

Cast iron Cast iron

Cast iron Cast iron

Stainless steel 5

Bronze 6

Bronze 7


stallation was prepared by Robert Magers, chief mechanical engineer, and Jerry Pontius, assistance chief mechanical engineer. Information supplied on the Bull- dog mine at Creede, CO, was prepared by T. R. Robert- son, resident manager.

Note 6 The estimated pumping costs at St. Joe Mineral

Corp.'~ Vibernum No. 28 mine are $0.034 per 1000 L ($0.13 per 1000 gal), including power, labor, and mechanical maintenance. The estimated purchase cost of the pumps, motors, and starters was $106,500, and the estimated total cost of the pump installation, including equipment, installation cost, pump-room excavation, electric cables and transformers, and pump column, was

Note 4 The information on the Lucky Mc mine in Wyoming

was prepared by J. F. Crouch, chief mine engineer.

Note 5 The Pilot Nob Pellet Co. of Missouri has advised

that the power cost at their operation is $0.042 per 1000 L ($0.159 per 1000 gal), and the labor cost is $0.0016 per 1000 L ($0.006 per 1000 gal). This totals to $0.068 per 1000 L ($0.256 per 1000 gal). The estimated cost of the pumps, motors, and starters purchased in 1967 was $82,140. Other estimated costs were $10,800 for the pump column, $3400 for the horizontal mine line, $90,000 for mining costs, $15,000 for mis- cellaneous costs, making the total installation cost $201,340. This information was provided by R. J. Zgonc, general superintendent.

$1,120,000. This information was supplied by the Min- ing Research Dept. of St. Joe Minerals Corp.


Corp.'s Vibernum No. 29 mine are $0.024 per 1000 L ($0.09 per 1000 gal), including power, labor, and mechanical maintenance. The estimated purchase cost of the pumps, motors, and starters was $18,500, and the estimated cost of the pump installation, including equipment, installation cost, pump-room excavation, electric cables and transformers, and pump column was $195,- 000. This information was supplied by the Mining Research Dept. of St. Joe Minerals Corp.


Table 8. Pump lnformatlon Summary+contlnued)

St. Joe Minerals Sunshine Mining UV Industries, St. Joe Minerals Corp., Indian St. Joe Minerals Co., Sunshine Continental

Corp.. Creek No. 32, Corp., Brushy Mine, Mine, Item Fletcher, MO Bonne Terre. MO Creek, MO Kellogg, ID Hanover, NM

Depth of Shaft. (ft)




Capacity, each pump, Us (gpm)


Motor power, each pump, kW (hp)


Pump control Year installed Pump manufacturer Motor manufacturer Suction lift or

flooded Pump type Sump retention time Pump column diam


Casing material Impeller material Wear-ring material Notest

41 1 (1 348) 252 (4Ow None

63 (1 31 7 (1 040) 298 (a) 2300 v, 96 amp Automatic 1975 Ingersoll-Rand AC 69-11 (20-ft) lift

Automatic 1967 and 1969 Peerless US Motors Flooded

Automatic 1967 Peerless US Motors Flooded

Automatic 1973 Peerless US Motors Flooded

Automatic 1978 B J US Motors Flooded

Vertical 8 hr 305 (12) [one] steel



Horizontal 7.4 hr 203 (8) [one] steel

Vertical 45 min 203 (8') [one] steel

Cast iron Cast iron Bronze 8



Cast iron Bronze Stainless steel 11

Cast iron Bronze Bronze 12

' Information either not provided or not applicable. tSee text for meaning of notes.

Note 8 ($0.11 per 1000 gal), including power, labor, and mechanical maintenance. The estimated purchase cost of the pumps, motors, and starters was $102,000, and the estimated cost of the pump installation, including equipment, installation cost, pump-room excavation, electric cables and transformers, and pump column was $1,075,- 000. This information was supplied by the Mining Research Dept. of St. Joe Minerals Corp.

The estimated pumping costs at St. Joe Mineral Corp.'s Fletcher mine are $0.040 per 1000 L ($0.15 per 1000 gal), including power, labor, and mechanical maintenance. The estimated purchase cost of the pumps, motors, and starters was $112,900, and the estimated cost of the pump installation, including equipment, installation cost, pump-room excavation, electric cables and transformers, and pump column was $1,190,000. This information was supplied by the Mining Research Dept. of St. Joe Minerals Corp.

Note 11 The estimated pumping costs at Sunshine Mining

Co.'s mine are $0.333 per 1000 L ($1.26 per 1000 gal), including power, labor, and mechanical maintenance. The 1976 purchase cost of the pumps was $6782 each. The cost of the 298-kW (400-hp) motors was $8479 each, and the cost of the starters was $4893 each. The total cost of the pump installation, including equipment,


Corp.'s Indian Creek No. 52 mine are $0.040 per 1000 L ($0.1 1 per 1000 gal), including power, labor, and mechanical maintenance. The estimated purchase cost of the pumps, motors, and starters was $56,033, and the estimated cost of the pump installation, including equipment, installation cost, pump-room excavation, electric cables and transformers, and pump column was $555,- 000. This information was supplied by the Mining Research Dept. of St. Joe Minerals Corp.

- -

installation cost, pump-room excavation, electric cables and transformers, and pump column, was $82,500. This information was supplied by the Engineering Dept. of Sunshine Mining Co.

Note 12 The estimated cost of the pumps, motors, and start-

ers at UV Industries operation in New Mexico was $18,000. This information was supplied by R. C. Weagle, vice president in charge of operations.


Corp.'s Brushy Creek mine are $0.029 per 1000 L

LINDERGROLIND MINING METHODS HANDBOOK

Table 8. Pump lnformatlon Summary-+continued)

Magma Copper Magma Copper UV Industries. Hecla Mining Co., Hecla Mining Co., Co., San Manuel Co., San Manuel Continental Star-Morning Star-Morning Shaft 5, Shaft 5.

Mine, Mine, Shaft No. 4, Mine, Shaft No. 4, 2075 Level, 2675 Level, Item Hanover, NM Wallace, ID Wallace, ID San Manuel, AZ San Manuel, AZ

Depth of Shaft, 452 161 5-762 2225-1 61 5 1257 1257 In (ft) (1 483) (5300-2500) (7300-5300) (41 23) (4 1 23)

Total water pumped, 11 47 41 240 256 Us (gpm) (1 75) (740) (650) (3800) (4050)

Pump level interval, 253 853 61 0 31 1 183 m (ft) (830) (2800) (2000) (1 020)

2 7 (600)

No. pumps on each 2 3 10 level

Capacity, each 63 44 50 50 [51 and 57 [21 38 pump, Us (gpm) (1000) (700) (800) (800 and 900) (600)

Total head, each 305 853 625 31 9 189 Pump, In (ft) (1 (2800) (2050) (1 045) (620)

Motor power, each 298 522 522 224 [51 and 1 49 Pump, kW (hp) (400) (700) (700) 261 121 (200)

(300 and 350) Motor current, 60 2300 v 2400 v 2400 v 2300 v 2300 v

Hz, 3-phase Pump control Automatic Automatic Automatic Automatic Automatic Year installed 1976 1975 1975 1 970 1971 Pump manufacturer Ingersoll-Rand Ingersoll-Rand Ingersoll-Rand B 8 J [51 and Pacific Pump

Ingersoll-Rand [2] Motor manufacturer Westinghouse Westinghouse Westinghouse General Electric General Electric

8 US Motors Suction lift or

flooded Pump type Sump retention time Pump column, diam


Casing material Impeller material

Wear-ring material Notest

Flooded

Horizontal 1 hr 203 (8) [one] steel

Cast iron Bronze

Bronze

Flooded Flooded Flooded

Horizontal Horizontal Horizontal 1.3 hr 3.7 hr 10 min 254 (10) [one] 254 (10) [one] 305 (12) [two] schedule80840 schedule80840 steel steel Cast steel Cast steel Steel Chromium-nickel Bronze Bronze steel Stainless steel Stainless steel Stainless steel 13 13 14

Horizontal 3 min 305 (12) [two]

Steel Bronze

Bronze 14


ANCILLARY EQUl PMElVT

Table 8. Pump Information Summary--(continued)

Magma Copper Magma Copper Magma Copper Magma Copper Magma Copper Co., San Manuel Co., San Manuel Co.. San Manuel Co., San Manuel Co., San Manuel

Shaft 5, Shaft 5, Shaft 5, Shaft 1, Shaft 1, 2950 Level, 3530 Level, 4123 Level, 820 Level, 1475 Level,

Item San Manuel, AZ San Manuel, AZ San Manuel, AZ San Manuel, AZ San Manuel, AZ

Depth of Shaft, f7-I (ft)


Pump level interval, f7-I (ft)


Capacity, each Pump, Us (gpm)




Pump control Year installed Pump manufacturer

Motor manufacturer

Suction lift or flooded

Pump type Sump retention time Pump column, diam


Casing material Impeller material Wear-ring material Notest

Automatic 1973 Pacific Pump

General Electric & US Motors Flooded

Horizontal 5 min 203 (8) [onel

Carbon steel Stainless steel Stainless steel 14

Automatic 1974 B & J and Ingersoll-Rand General Electric

Flooded

Horizontal 5 min 305 (12) [two]

Iron Bronze Stainless steel 14

Automatic 1974 B & J

B & J

Flooded

Submersible 60 min 203 (8) [two] 305 (1 2) [one]

Iron Bronze Bronze 14



Horizontal Booster pumps 305 (1 2) [two] 203 (8) [one]

Steel Bronze Bronze 14



Horizontal 25 min 305 (12) [two] 203 (8) [one]

Steel Bronze Bronze 14

Information either not provided or not applicable t See text tor meaning of notes.


Table 8. Pump Information Summary+contlnued)

Magma Copper Magma Copper Magma Copper Magma Copper Magma Copper Co., San Manuel Co., San Manuel Co., San Manuel Co., San Manuel Co., San Manuel

Shaft 1, Shaft 1, Shaft 1, Shaft 1, Shaft 5, 2075 Level, 2375 Level, 2675 Level, Bottom Sump, 1055 Level,

Item San Manuel, AZ San Manuel, AZ San Manuel, AZ San Manuel, AZ San Manuel, AZ

Depth of Shaft, 863 863 863 863 1257 In (ft) (2830) (2830) (2830) (2830) (41 23)

Total water pumped, 189 50 91 3 240 Us (9Pm) (3000) w"3 (1 450) (50) (3800)

Pump level interval, 200 91 91 47 322 (ft) (600) (300) (300) (1 55) (1 055)

No. pumps on each 12 3 6 2 7 level

Capacity, each 38 38 38 95 50 [5] 8. 57 [21 Pump, Us ( 9 ~ m ) (600) (600) (600) (1 500) (800 8. 900)

Total head, each 191 94 191 61 322 Pump, In (ft) (625) (31 0) (625) (200) (1 055)

Motor power, each 149 75 149 56 and 67 224 Pump. kW (hp) (200) (1 00) (200) (75 and 90) (300)

Motor current, 60 2300 v 2300 v 2300 v 2300 v 2300 v Hz, 3-phase

Pump control Automatic Automatic Automatic Automatic Automatic Year installed 1958 1968 1968 1973 1970 Pump manufacturer Pacific Pump Pacific Pump Pacific Pump Fly@ B 8. J and

Ingersoll-Rand Motor manufacturer General Electric General Electric General Electric Flygt General Electric

& US Motors & US Motors & US Motors Suction lift or Flooded Flooded Flooded Flooded Flooded

flooded Pump type Horizontal Horizontal Horizontal Submersible Horizontal Sump retention time 10 min 5 min 5 min 2.25 hr Booster pump Pump column, diam 305 (12) [two] 305 (12) [one] 305 (12) [one] 102 (4) [one] 305 (12) [two]

[mm (in.)] and 203 (8) [one] 152 (6) [one] material

Casing material Steel Steel Steel Aluminum Steel Impeller material Bronze Stainless steel Bronze Steel Bronze Wear-ring material Bronze Stainless steel Bronze Stainless steel Notest 14 14 14 14 14

Information either not provided or not applicable. t See text for meaning of notes.

Note 13 providing clear water to the 6RTL-6 pumps. The verti-

Hecla Mining Co.'s Star-Morning mine is illustrated in Fig. 28. The main components of the No. 4 shaft pumping system are the Ingersoll-Rand 4HMTA-9 and 6RTL-6 pumps, and the information herein pertains only to those pumps. Since the Star-Morning mine has been operating for many years and since the pumping system has undergone and continues to undergo almost continual change, it is impossible to define the cost of the entire system.

cal settler removes the considerable amounts of suspended solids caused by the hydraulic sandfill system used to backfill the stopes. Water jets near the bottom of the settler are used, together with frequent pumping, to remove accumulated slimes.

The total operating cost of the Star-Morning pumping system is approximately $0.25 per 1000 L ($0.93 per 1000 gal). This information was supplied by W. E. Crandall, chief engineer.

The ~HMTA-9 pumps, motors, and switchgear cost Note 14 approximately $106,000, and the entire 7300-5300-2500 Details of Magma Copper Mining Co.'s operations level installation cost approximately $600,000 (including at the San Manuel mine were provided by J. R. Tinnen, the 7500-level vertical settler). manager of Engineering and technical services, P. M.

The vertical settler was a "first" at Hecla Mining Castro, mine engineer, and V. S. Konur, chief design Co.'s mines in this district, and it has been the key to engineer.


Sloping Area

1450 LEVEL

8800 11 l o Burke (Hala) 2WO LEVEL ADIT(E1ev. 375011) * - - - - - - -- -- - ------ - .. .. . -

Z . ~ . R Z M R V . ~ H . P . . * ~ V . - %---'I 2300LEVEL

I I

\ 53673 LEVEL . ~ 50.000 GAL SUMPS '& (Elev. 450 11)

+ l u a f t *

Sloping Area

Water to I

-- . ' I

t

I 1 '2-1.RBRTL6,7Ol H.P.. 2400 V. i I I

4 -O-'.+-l

r..l

2-1.R.ZMRV.SOH.P.,440V. - I

i 2lWLEVEL

L--+ - - - I

4000 LEVEL !

I I

I + I

I I

I

t Sloplng ~ i e a

w r

z - i . k . zv r~vn ,m~ .~ . , *ov . , 2 3-1.R. 4HMTA-@

I

7300 LEVEL

7MLEVEL 2-1.R. ZRVH,J)H.P.

, , 2aX)LEVEL

I

t 1 0 . m 11 to Mullan 1 2500LEVEL ADIT(Y0RNINQ NO. 6) - - - - - :. + - - - - - - -*

ZWLEVEL (Elev. 3250 11)

77W LEVEL

7W7 LEVEL

(THICKENER) 8fW LEVEL (Elev. 2350 It)

~CLYGT 81804; 7% H.P. DUPLDC YUDPUWP

Fig. 28. Pumping system at the Star-Morning mine of Helca Mining Co. at Wallace, ID. Metric equivalents: ft X 0.3048 = hp X 0.7456 699 9 = kW.

l-l.R.ZRVH.20H.P..440V. W L E V E L

-0-..--J , I t


REFERENCES AND BIBLIOGRAPHY

Bogeat, J.R., 1963, "Naica Battles Water and Costs as Lead- Zinc-Silver Mining Goes Deeper," Mining World, Aug .

Brookes and Murdock, 1977, "Application of High Capacity, High Head Pumps for Mine Drainage Using a Flood Protected Pump Station," Fifth Technical Conference o f British Pump Manufacturers' Association.

Clarke, C.D., and Reinberg, G., 1956, "Corrosion Problems in Pumping Acid Mine Water," Trans. AZME, Vol. 205, pp. 821-825.

Corbett, R.P., and Ralph, F.E., 1968, "Dewatering with a 4,100-Ft Head Pumping Plant," Mining Congress Journal, Sept., pp. 33-43.

Ferguson, C., and Morris, M., 1970, "Mine-Water Treat- ment, Inco Sudbury Operations," Ontario Water Re- sources commission.

Hall, J.G., 1949, "History of Pumping at the Chief Con-

solidated Mine, Eureka, Utah," Trans. AZME, Vol. 184, pp. 229-234.

Hydraulic Institute, 1975, Hydraulic Institute Standards. Loofbourow, R.L., and Lehmann, E.K., 1968, "A Mine

Flood, Vancouver Island," Preprint 68AG346, SME Fall Meeting, Minneapolis, MN.

Miller, H.W., and Jolley, D.H., 1964, "Flooding and Re- covery of the Jefferson City Mine," Mining Congress Journal, Jan.

Monroe, H.L., 1965, "Design of a Water Settler at Pea Ridge," Mining Engineering, Dec., pp. 81-84.

Saul, H., 1978, "Current Mine Drainage Problems," Trans- actions, Institution of Mining Engineers, Sec. A, pp. le-9e.

Westaway, C.R., and Loomins, A.W., 1977, "Cameron Hydraulic Data," Ingersoll-Rand Co.

Wiles, G.M., 1943, "Development and Dewatering Practices at Park City Consolidated Mines," Trans. AZME, Vol. 153, pp. 115-120.

Chapter 3. Mine Pumps

Documents

Transcript of Chapter 3. Mine Pumps