CHAPTER 10

W A T E R I N T H E S U R F A C E M I N E S AND M I N E P U M P S

W A T E R IN T H E S U R F A C E MINES

) ^ Surface run o f f due to rain, flood, snow and ground water are the sources o f potential hazards in surface mining
system particularly during rainy season. Beside above water may also flow into surface mines from the sea by the tidal
wave during typhoon, from the river during flood, from the isolated water pockets and flooded mine when accidentally
they are touched. The rain and snow water (in cold climatic region) over a surface mining area escape by evaporation, a
part o f them enter by infiltration through the permeable strata into the ground and reach the ground water table alter
saturating above A quantity o f them also accumulate over the surface as a surface run off. The water inflow into ihe
ground depends upon the geology, surface topography, permeability area o f cross section, hydraulic gradient, poros.il) of
rock, present o f impervious structures, joints and fissure in the rock, etc. I f the workings in the surface mining system arc
below the ground water table, the ground water becomes a surface run o f f i n relation to surface mining operation.

The water which creates problems is as following-

• Decrease slope stability o f the benches and also causes erosion in the pit walls,
• Decrease slope stability o f the wall o f spoil dump and causes problems in subsurface drainage,
• Causes machine delays, interruption in production, partial or total damage o f the mine. Sudden in rush of water
may cause damage o f machine and loss o f life.
• Increase cost o f production by spending more money for pumping operation and for other reasons related to the
dealing o f water,
• Reduces the efficiency o f man and machine and cost o f production becomes higher,
• Caves down the blast holes,
• Increase the equipment operating and maintenance cost, decrease the tyre life,
• Wei ore/coal stick onto the belt surface and crusher plant. Cost o f transporting and processing o f ore increase.
• It has a detrimental effects on some o f the explosives e.g. A N F O . Hence special type o f gelatinous cartridge
explosives or A N F O in the polythene bag should be used,
• l i dissolves some o f the soluble minerals and chemical ingredients like sulfur dioxide,etc.

• l i pollutes surface run o f f particularly when water percolates through the overburden dump.

Controls

The following controlling measures may be adopted-

1. The pit floor should be sloped (around 2°) towards the extraction side to drain out rain water when the floor
rock is impermeable in nature, pit is above the water table, slope is steeper and the quantity o f rain falling is very
nominal.
2. Surface water body like river, lake, etc. may be diverted or drained o f f after constructing sufficient amount o f
drain or ditches. Pumps shall be installed in the sump. I f the quantity o f water is small, a small submersible pump is
sufficient whereas i f the quantity is very high, a high capacity with optimum headed centrifugal pump shall be installed.
Sumps are generally located at the lowest point o f the pit. Pumping is exclusively essential when the watery condition o f
the pit is heavy. Pumping should be a very simple and flexible in operation. They can be used efficiently from small to
large inflow with a least cost and a large number pumps may be installed in the same sump. I f the pits are made by
diverting surface lake or river, the amount o f water in the working w i l l be very heavy and very high capacity pumps are
necessary to remove water. Since more amount o f suspended solids and acids are present with the mine water, ihe pump
structures must be made o f abrasion and corrosion-resistant materials. Pumps are to be reliable in operation, durable, ease
in maintenance and also can be controlled automatically. Pumps are selected mainly considering the quantity o f waier to
be pumped, total head, dirt content in the water, economical performance, operating and maintenance cost, life range, etc.
Both horizontal centrifugal pump and submersible vertical turbine pumps are used in the sumps. In same o f the open cast
mines pontoon mounted centrifugal pumps are also used to deal with heavy rain water during the monsoon.
 Water in the Surface Mines and Mine Pumps 289

Sometimes sufficient number o f deep wells located properly inside and outside the pit limits are also drilled to
pump out water when both the quantity to be pumped and head is within the efficient limitations o f the borehole
submersible pumps. Flow o f water into the borehole shall be consistent and very high. However with this method exact
location o f water table and its depth should be known. B y introducing this method pits are kept free from sumps, pumps,
pipelines, power lines, etc., and also the amount o f construction o f ditches or drains are very less. Loading and blasting
operation generally do not cause any interference to the system and benches are also become more stable. Steady and
uniform pumping, ease in maintenance o f machine, road, bench floor, etc., supply o f clean water to be used for other
purposes are some o f the good points under it merits. W i t h this system accumulation o f run o f f water and mud are
reduced and water from the toe o f the benches can efficiently be dewatered. However the system is expensive, time
consuming and water table also lower down. The method w i l l be unsuitable under unfavorable condition. Submersible
vertical turbine pumps are commonly used for deep well pumping. Pumps are basically selected based on the depth and
diameter o f the well; besides capacity and head o f discharge.

Sump

Sumps are excavated at the lowest point o f the pit to collect water. Its depth is generally selected based on the
type of pumps, volume o f water to be accumulated, peak volume o f water during rains, discharge capacity o f the pump,
etc. However a temporary sump can be excavated to collect water at a particular point from a bench or a number o f
benches. It may be used to collect water from the main sump during peak inflow o f water. The size o f the sump shall be
so sufficient that-solid particles settle down prior to pumping. But a sump require more space, it interfere with the
workings at its level with the pipelines, cables, pump structure, etc.

Improper blasting operations also damage the pumps and their accessories and also pumped out water contains
abrasive materials, acids and other dirt. In most o f the cases, the lowest point o f the mine is slanted in such a manner thai
water is accumulated at the corner point at the bottom most place o f the mine. There a small excavation is made to
accommodate the suction ranges o f the pumps. From that place water is pumped out with the help o f pontoon mounted
centrifugal pumps.

In opencast mining system sump is generally built in the lowest most point o f the pit. It must be adequate in
capacity to deal not only the normal water but also any sudden irruptions o f water and quantity o f water due to heavy rain
during monsoon. Hence pumps o f adequate capacity and adequate numbers including a standby facility are to be
selected. From every bench above the sump level, water is diverted with the help o f ditches made near to the edges o f the
benches. The inclination o f drains/ditches should be such that the velocity o f water in it should be around 0.8 m/s to
lm/s. Capacity o f the sump depends upon the amount o f water flowing in a unit time and a sump capacity should be
planned for a water influx over a period o f 24 - 36 h. Since a pump on an average runs 6 to 8 h per day, numbers o f
pumps are also to be selected accordingly.

Danger and Hazards due to Water

Water run o f f from surface mine workings and mining properties and infrastructure for production and
overburden benches, quarry roads, dump yards, etc. may cause mine inundation, jeopardize safety and working
environment o f the mine and surrounding localities. It also causes serious environmental impacts to neighboring land and
waler resources. The most serious environmental problem by water and resources is the presence o f siltation which is the
after effect o f erosion, transportation and sedimentation o f suspended-particles.

The sources o f water includes annual heavy rainfall above 970 m m (rainfall between 790 mm to 970mm with
10% variation is considered as normal) and surface run o f f during monsoon, subsurface water in the ground water table,
aquifer, snow (in cold countries), running water bodies like river, streams, drains, and flood, etc. Water resources are
damaged by mining excavation work, dumping yard, lowering down the water table due to pumping out o f mine water
from the excavated area, etc. Surface mines must be adequately protected from the danger due to inrush o f water. Erect
embankments out o f quarry overburden debris when there is the presence o f river, jores or drains, etc. surrounding the
mine. The embankment should be sufficiently higher than the H F L (highest flood level) o f the river, drains or jores and
designed in such a manner that it can withstand the likely head o f water with a high factor o f safety. In case o f presence
of large size boulders in each layer o f boulders, they should be covered by a layer o f earth or alluvium to fill up the space
290 Surface M i n i n g Technology

in between the blocks. The quarry debris which make the embankment must be compacted. The side o f the river or
stream or drains should be pitched with stoke to prevent scouring action o f moving water bodies. To guard against the
land erosion, trees shall be planted in enough quantity on the embankment. I f the mine working is within 15 in o f Ihe
bank/HFL o f Ihe river, stream, lake, etc., a special permission from the D G M S should be obtained. A careful assessmeni
of the danger of inundation due to surface water shall be done prior to the onset o f monsoon and all the precautionary
measures are to be taken and their effectiveness should be checked out regularly. The mine management through surprise
inspection should pay particular attentions on the markings o f the H L F , effectiveness o f signaling and communication
systems, etc.

A standing order regarding the withdrawal o f the persons should be framed out and enforced. A l l the concerned
persons should be made familiar with the standing order and several mock rehearsals should be conducted time to time.

An effective water drainage plan and design must be prepared for drainage o f the mining area, slope of the
water drainage system, flow velocity, vegetation characteristics, scouring velocity o f water into the soil, etc.. for effective
control of land erosion and arresting o f suspended particles in the open area. For maintaining safe and unhindered
production enough dewatering facilities with heavy pumping arrangement must be introduced. The subsurface ground
water table is either brought below the lowest level o f mine working or flow o f water from the water table is lo be
controlled. Dewatering plan depends upon the size o f the excavation, amount o f rainfall, snowfall, surface topography,
permeability of ihe strata, hydro-geological characteristics o f rock, etc. The water after lowering below ihe water lable
and into the sump o f lowest level o f working is pumped out o f the mine with the help o f a pump having sufficient
capacity.

If Ihe surface mining system situated at the hill top terrain, the run o f f water is diverted to a particular section o f
ihe mine and water allows to flow along the steep hill slope. Non- pumping drains are prepared for gravity flow wherever
il is possible and adequate sedimentation control facilities should be provided to off load the suspended particles from ihe
mine run off. The lower most bench should be sloped upward at a gradient o f 1 in 25 whereas the top benches are sloped
downward at a gradient o f 1 in 50 so that all the rain water come down to drain formed all along the edges o f ihe benches
and then canalize the water in the lower most bench from where water may coursed through a water trench o f 70 - 100 m
long and 15 m wide having a gradient o f 1 in 35 to 1 in 25 for discharging the mine water to adjoining water course. To
avoid percolation o f water through the loose waste rock dumped in the dump yard, a steel channel having base width
around 2m lo 2.5 m having side slope 6 0 ° to 70° may be made in 1.5m to 2 m section and embedded before ihe onset of
ihe monsoon in the drainage trench every year. Similar channels with baffle plates may also be embedded all along the
slope o f ihe dump to avoid erosion o f gully and formation o f gorge. After the monsoon is over those steel channels are lo
be removed for starting the dozing operation o f Ihe wastes. Permanent drains o f 3m to 5 m width with check dam
(baffles) at interval o f 30m to 40 m shall be constructed along the gentle slope to arrest the suspended solids. The slope
of ihe drain should not exceed 1 in 50 so that the suspended particles get settle therein. In steeply inclined deposits in
hilly terrain to arrest rolling big boulders and filtration o f fines a buttress rock, filter wall having a minimum width at the
top around 5m, minimum height around 3 m having side sloping at 1 in 5 to 1 in 3 may be constructed below the lower
most toe o f Ihe dump benches.

This arrangement w i l l provide efficient reclamation, re-vegetation, green carpeting, etc., over the lop and slope
of (he dump. The natural water system which is affected due to various reasons like water drainage, erosion from dump
and chemical effect like acid or alkaline o f the strata should be treated properly to protect environment. Due care should
be taken against the water getting polluted from mines workshop, coal handling plants and other mine infrastructure. The
sedi mental ion created by water due to scattered dump are also to be taken due care. Quality o f water stored in the
excavaled portion o f the opencast mining area may improve because o f less mining activity, restriction o f land erosion
due lo vegetative capping over the waste dump and also by proper treatment o f water. Water accumulated in ihe
excavated area as well as leached into the ground water are polluted by the toxic substances from overburden dumps and
active benches like arsenic, cobalt, zinc, lead, nickel, tin, titanium, etc., which are very much soluble in acidic water.
Oxidation mixing or leaching o f pyrites, leaching and mixing o f salts o f calcium, magnesium, sodium, etc. o i l . grease and
other effluents discharged from the heavy earth moving machineries, addition o f solid concentration particulates like
mineral, rock, etc. causes water pollution.
 Water in the Surface Mines and Mine Pumps 291

I L O Recommendation

Regarding water management the I L O recommendations are as follows:

• Prior to the commencement o f excavation, the operator or manager o f an opencast mine should take steps lo
ensure that a thorough hydrological and hydro-geological assessment are made on the surface and subsurface
conditions o f the area lo be mined.
• When mining in waler-bearing strata or near to the rivers, lakes and seas and potentially flooded underground or
surface mining area are conducted , provision should be made for safety pillars to be left to prevent any
breakthrough. It should be the responsibility o f the mine operator or manager to ensure that no mining takes
place within the boundaries o f such pillars.
• The mine operator shall ensure that where mining is carried out in areas liable lo flood from any source or
because o f any circumstance, special protective schemes are to be designed and implemented.
• In case where a lowered water table is maintained with the aid o f drainage shafts, the following safely measures
should be ensured:
1. The installed pump capacity should be such that the maximum daily inflow can be lifted out not more
than 20 hours;
2. Sland-by pumps should be installed with a capacity o f not less that 25 per cent o f Ihe lotal installed
capacity;
3. The electrical feed to the pumps should be duplicated and each feeder capable o f carrying the
maximum load o f the installation;
4. Sland-by pumps should be so equipped as to start automatically in case o f failure o f a main pump
5. Where drainage tunnels are required to be driven in water-bearing strata, pilot holes should be drilled
to a depth o f not less than 5 m; and
6. The sump for the main pumping installation should have a capacity equal to not less than four hours o f
normal water inflow.
• Sinkholes and surface subsidence occurring as a result o f dewatering should be so enclosed as lo prohibit ihe
access o f unauthorized persons.

MINE PUMPS

Mine pumps are the most vital equipment for dewatering purpose both for surface and underground mining
systems. Pumps can basically be grouped into two types viz. kinetic and positive displacement types. In positive
displacement type pumps single/multi acting piston ram or diaphragm type reciprocating pumps and screw and vane
type rotary pumps are very important. In kinetic pumps centrifugal, turbine and axial-flow pumps are commercially very
important. These kinetic pumps are very compact and efficient. Beside above submersible pumps, borehole pumps, etc..
are also gaining wide acceptance in the mining industry. In surface mining system ,the most common types o f pumps arc
used for dewatering purpose are centrifugal pump, turbine pump, submersible pump, etc. However, in some special cases
for small discharging purpose mono pump and bore hole pumps are also employed. In India, the capacity o f pumps for
opencast mines falls in the range o f 400m /h to 700m /h at heads between 40m to 250m. Pontoon mounted pumps are
3 3

being used profoundly to save the pumping station in case o f heavy inrush o f water or during excessive rain.

Selection

During selection o f any pumps, the following main points are to be kept in the mind: discharge requirement,
lotal head, friction head, exit losses, volumetric, mechanical and overall efficiency, nature o f water (acidic or alkaline),
temperature, amount, size and nature o f solid particles present in the water, life o f the pump, reliability, safely, whether
lo be used for continuous or intermittent duty, variation o f capacity and head, indigenous or imported, availability and
cost of spare parts, cost o f the pump whether lo be used for temporary purpose or permanently, availability o f lype of
power, availability o f electrical power and its voltage limit, whether to be used in the face, intermediate points or in ihe
main sump. elc. B u i most important point is the economical consideration which is nothing but the dewatering o f mine
water with highest possible efficiency and in cheaper means. During calculation o f pumping cost, depreciation and
interest on working capital, power cost, operating and maintenance cost, overhead cost, etc. are to be included.
292 Surface M i n i n g Technology

Centrifugal Pump

l l consists o f a volute casing inside o f which an impeller is incorporated mounting over a steel shaft. The ends
of the steel shaft passes through the casing and stuffing boxes are provided there in to seal water. A t one end bearing is
provided in the water- tight cap whereas at the outer end bearing is provided inside the extension o f the end cover. The
impeller is provided with vanes. Water is sucked through the inlet port connected in the centre o f the impeller (which is
also called the 'eye ') .As the impeller rotates , water passes tangentially round the periphery o f the casing by the
centrifugal force generated by the impeller vane and thrown into the volute chamber from which water finally discharges
through ihe delivery main ( Fig.10.1). A centrifugal pump needs priming to create vacuum in it. Priming is the filling up
the casing and the suction pipe line with water/liquid. When impeller rotates the kinetic energy is generated in ihe
water/liquid due lo the centrifugal forces produced by the blades o f the impeller and water from the impeller blades
(curved backward as compared d with the direction o f rotation) thrown o f f at an increased velocity and pressure into the
volute casing. Here because o f the larger cross sectional area, the velocity decreases (i.e. kinetic energy decreases)
gradually and pressure energy in the water increases correspondingly accordance with the Bernoulli's theorem and Ihe
principles o f conservation o f energy.

Bernoulli's theorem

— = — = P r essure head
g w
2
V
If kinetic head =
2g
Potential head =z

P V , . . .
Then 1 \- Z = constant . Where p=pressure in k g / c m " , v= velocity o f water in m/s
w 2g
g= acceleration due gravity =9.81 , z = Datum height in m

From the volute casing, the liquid/ water is expelled outside with high pressure energy and little kinetic energy
and it w i l l create a negative pressure inside the impeller. Because o f this negative pressure, fresh water/liquid enters into
ihe impeller and in this way continuity o f the liquid/water flow is maintained. The casing is proportional in such a
manner that there is a gradual reduction in the velocity o f the water/liquid. The lion share o f the pressure is created
within the impeller itself and the rest amount is produced in the volute casing.

Starting and stopping of pumps including priming

After opening the air cock, i f it is found that there is either little or no water in the suction range, water is to be
poured into it until water overflows. Water w i l l be filled up from the sump level to the main valve, Close the air cock and
check for any leakage o f air/water in the same suction range. After closing the main valve, start the pump with lower
speed till Ihe pressure gauge indicates the required pressure. This can be checked by opening the air cock o f the pump
and when the water w i l l eject out with high pressure it w i l l mean that the pump is working satisfactorily. Alter closing
the air cock allow pump to run in the full speed. Always open (to combat overloading) the main valve to discharge water
through the delivery pipe range. During stopping the pump first close the main valve and then o f f the motor o f the pump.

For multistage centrifugal pumps the procedure for starting and stopping o f the pump will be the same as
mentioned in the forgoing paragraph but the air cocks o f each stage has to be opened up and closed during the priming
operation.

Basic characteristics of the centrifugal pumps

The basic characteristics o f a centrifugal pump are as follows:

• The pressure which is developed by each impeller directly varies as the square o f the speed.
• The quantity o f discharge varies directly with the R.P.M. o f the impeller.
• The requirement o f power for a centrifugal pump varies directly as the product o f the pressure and quantity.
 Water in the Surface Mines and M i n e Pumps 293

Basic components of a centrifugal pump (Fig. 10.1)

A centrifugal pump consists o f the following basic components-

H E A D DUE 10 F R I C T I O N IN T H E SUCTION
^ RANGE

F i g . 10.1 : A Schematic Line Diagram o f a Contrifugal Pump along with all Accessories.

Impeller : Impellers are basically classified into single suction impellers and double suction impellers. It is a circular
disc type body having a series o f backward curve vanes. Impellers are either closed type, open type or semi-open type.
The impeller is mounted over a shaft and rotates inside the casing. The shaft is connected to the motor via gearbox and
fluid coupling. Materials o f impeller are bronze, cast steel, monel metal (to resist against the acid mine drainage), etc.

Casing : The casing covering the impeller is designed in such a manner that the kinetic energy o f the water at the
discharge end gradually converts into pressure energy and finally enters into delivery pipe range with high pressure
energy and little kinetic energy. There are wide varieties o f casings are available in the market out o f which volute
casing, vortex casing, casing having guide blades are very common. Materials which are used for manufacturing o f
casings are cast iron, cast steel, alloy steel, bronze (for corrosive water), etc.

Shaft : The shaft over which the impellers are mounted and which is connected to the drive unit is made from forged
steel, monel metal, stainless steel, etc.

W e a r rings Provisions are also there for fitting wear rings on the impeller necks. This type o f rings are made from
monel metal, bronze, cast steel, stainless steel depending upon the condition o f uses.

Hearings : The bearing housings are carried in rigidly constructed brackets, cast integrally with the pump casing and the
housings are dowelled to provide positive location. Both ball and roller bearings are used in both the drive and non drive
ends.

Stuffing box : The stuffing box is provided with conventional packed glands using lubricated cotton packing.
Mechanical seals are also sometimes provided. The gland is o f split construction which can easily be removed for
accessibility for the packing removal. A lantern ring is fitted to receive the pumped liquid at delivery pressure to
lubricate packing and also to provide a seal to prevent the ingress o f air. Besides .above some other fillings and
accessories are also attached in the pump suction and delivery ranges which are as follows:
294 Surface M i n i n g Technology

• Suction and delivery pipes-They are fitted in the suction and delivery end o f the pump inlel and outlet
respectively.
• Funnel for priming-It is used to prime i.e. to pour water to fill the pump and suction range.
• A i r cocks-To release air from the pump and the casing during priming this type o f air cocks are used.
• Pressure and vacuum gauges-Pressure and vacuum gauges are attached just after the pump outlel and before the
pump inlet respectively to measure the pressure.
• Main valve-It is attached in the delivery pipe range.
• Retaining valve-It is connected with the delivery pipe range just above the main valve.
• By-pass valve-To by-pass both the main and retailing valves in the delivery pipe range by-pass valve is
provided.
• Strainer-It is fitted at the inlet end o f the suction pipe range to segregate out any solid panicles mixed with
water.
• Fool valve-It is a non-return valve fitted in the suction pipe range just above the strainer to reiain water/fluid
column in the suction pipe range.
A l l the above accessories and fittings are also provided in the turbine pumps too.

Multi-Stage-Centrifugal Pump

In case o f multistage centrifugal pump the number o f impellers mounted over the shaft is more than one (Fig.
10.2). So in this case when impeller rotates, water from the suction range enters into the inlet o f the first impeller and is
discharged at the outlel with increased pressure and reduced kinetic energy ( K . E ) as discussed previously. The high
pressure water from the outlel o f ihe first impeller enters into the inlet o f the second impeller through the pipe connecting
outlet of the firsl impeller to the inlet o f the second impeller. A t ihe outlet o f the second impeller there is the
development o f further higher pressure as compared to the outlet pressure o f the first impeller. In this way pressure o f
water goes on increasing from one impeller to another one at the cost o f successive reduction o f K . E . Finally the water)
liquid comes out o f the outlel o f the pump with having a very high pressure but low K . E . '

Fig. 10.2 : A Schematic Line Diagram o f a Typical Centrifugal Pump.

 Water in the Surface Mines and Mine Pumps 295

Advantages and disadvantages of a centrifugal pump

A centrifugal pump offers the following main advantages-

• It produces uniform pressure with wide range o f capacity variation.
• Higher velocity in the suction range.
• The pump is very compact, simple, light in weight, produces less vibration, noise, and also the pump has only
fewer mechanical parts/components.
• Initial capital requirement to purchase the machine is less as compared to a reciprocating pump.
• It does not produce any pulsation during discharging o f water/liquid.
• l l requires less space, and low cost foundation as compared to the reciprocating pump.
• Load on the motor is more uniform as compared lo a reciprocating pump.
• l l is applicable for high quantity and small head.
• Installation is easy.

• It's operating characteristics are also very much flexible.

Disadvantages
ll has the following main disadvantages-
• It has the lower efficiency as as compared d to a reciprocating pump. In case o f higher viscosity it's efficiency
further decreases.
• Very high discharge pressure cannot be achieved with this system.
• Shorter life, high power cost, requirement o f skilled manpower for operation and maintenance, inaccessibility in
the internal parts, higher speed susceptible to greater wear in the pump parts, etc. are the other inherent demerits
in this system as compared lo the reciprocating pumps.

• Suction lift should be the small.

Uses
The centrifugal pumps are available in the range starting from very small quantity to as much as quantity 20000
mVhour and head ranging from 5m to 200 in. However, higher head is possible with multistage pumps and higher speeil
motors. Centrifugal pumps are used in mining industry for dewatering from the mine sump, water logged area, main dip
during shall sinking operation, etc. Beside above this type o f pumps are used for coal/mineral washing, leaching, waste
disposal, boiler feed, spraying purposes, feeding in the condenser o f the mine air compressors, etc. The specification o f
some o f ihe centrifugal mine pumps are given below (Table 10.1).

Table : 10.1 Specification o f some o f the mine pumps

Pumps Quantity Head Power Voltage Material Price

(l/s) (m) (kW) (Volt.) used Rupees in lakhs
(year 2003)
M a i n Pumps
Centrifugal
(Flame Proof)
38 90 55 550 Bronze 4.30
38 150 90 550 Stainless 6.60
38 200 110 550 Bronze 7.30
60 300 265 3300 Bronze 19.00
75 300 310 3300 Bronze 21.00
80 120 135 3300 Stainless 14.50
296 Surface M i n i n g Technology

Table 10.1 continued

Face Pumps
Centrifugal
(Flame Proof) 15 30 7.5 550 Special A l l o y 1.00
20 60 22 550 Special A l l o y 1.10
Submersible 30 100 45 550 Bronze 2.80
Pumps 38 100 90 550 Bronze 5.80
60 230 260 550 Bronze 26.60

POWEN pump factory o f Poland manufactures various types o f centrifugal pumps out o f which HC series pumps are
worth lo mention. These pumps are heavy duty .single stage horizontal pumps with closed impellor. These pumps are
compact and robust design , able to pump mixtures containing up to 50% o f solids by volume, impeller neck adjustable,
hydrodynamic shaft seal , no external water needed , can operate in series and very easy to maintain. Table 10.2 shows
some o f ihe centrifugal pumps manufactured by the P O W E N pump factory.

Table : 10.2

Pump type Capacity Head Power r.p.m M a x i m u m solid size

(nrVh) (m) (kW) (mm)
HC 125 250 45 44 1470 30
HC150 400 63 100 1470 25
HC200 800 115 300 1470 44

T u r b i n e Pump (Fig. 10.3)

A turbine pump consists o f a number o f impellers which are mounted over the same shaft. When impellers
rotate, water from the suction range enters into the first impeller via the 'eye' o f the impeller and is discharged al the
outlet with increased pressure and less K . E . The outlet water from the first impeller enters into the inlei o f the second
impeller through the stationery diffusing channels o f the diffuser surrounding the impeller. In the diffusing channel
velocity o f the water is reduced and the K . E is converted into the pressure energy, intensity o f which depends upon the
velocity o f water ejected out from the impeller. The same process is repeated again and again during movement of water
from one impeller to the other and ultimately water is delivered into the delivery pipe range with a very high pressure but
with a little velocity.

This development o f high pressure is the sum o f the head developed at each stage (each impeller) i.e. in other
word the total effect is cumulative. M a x i m u m amount (more than 50%) o f increase in pressure takes place in the
impellers and the rest amount in the diffusing channels. Difference between the multistage centrifugal pump and the
turbine pump is that, in the turbine pump the impellers are surrounded by a series o f stationary guide diaphragms which
are termed as diffusers. T o counter balance the axial thrust the discs are balanced by reversing half the total number o f
impellers in the either half o f the mounted shaft as shown in the figure (10.3). The main parts o f a turbine pump is the
pump casing, impellers, stuffing boxes, diffusing channels (these are formed by the diaphragm which are connected in
ihe inner periphery o f the outer casing), etc.

Fig. 10.3 : A Schematic Line Diagram o f a Turbine Pump.

 Water in the Surface Mines and Mine Pumps 297

Water h a m m e r

Water while flowing through a pipe posses some momentum on account o f its motion. It has been experienced
that i f the flowing water is suddenly brought to rest by closing the valve, its momentum w i l l be destroyed causing a very
high pressure on the valve. This high pressure w i l l be followed by a series o f pressure vibrations. The pressure vibrations
may set up noises in the pipeline which is known as knocking. Such a knocking often heard in water pipe i f a lap is
turned o i l quickly. The sudden rise o f pressure in the pipeline is known as hammer blow or water hammer. Sometimes
this hammer blow is so high that it may even burst out the pipe. It is thus obvious that the valves o f the pipeline or
penstocks should always be closed gradually.

At the time the valve is being closed, the fluid in the pipe is moving possessing kinetic energy (K.E). With
sudden closure o f valve the K . E has to be converted into internal energy with a rise in pressure. Actually a sudden
pressure pulse is formed at the valve and this pulse travels backwards at the speed o f sound wave setting up reflected
pulses. This behavior o f the flow is termed as the unsteady flow. The magnitude o f the pressure rise and falls depends
upon the speed at which the valve is closed. In the process o f slow closing o f valve the whole mass o f fluid in the
pipeline is decelerated and the inertial pressure depends upon the length o f pipe and the time taken in closing the valve
which results the deceleration o f water. However, in a sudden closure o f valve the initial pressure created is independent
of length and time and depend upon the initial velocity o f fluid and the velocity o f sound wave in the fluid. The clastic
properties o f pipe material and the flowing fluid are also taken into account for deriving the equation o f the inertia
pressure.

Cavitations

If the pressure at any point inside a pump drops below the vapor pressure corresponding to the temperature o f
the liquid, the liquid w i l l vaporize and from cavities o f vapor. The vapor bubble are carried along with the steam until a
region o f higher pressure is reached when they collapse with a tremendous shock on the adjacent walls. This
phenomenon is called the cavitations. The sudden inrush o f liquid into the cavity created by the collapsed vapor bubbles
causing mechanical destruction sometimes apparent as a boring action which might be called erosion. Chemical reaction
between the gases and metal also occurs and results in corrosion and additional destruction o f the metal. Other
undesirable feature is the accompanying noise, varying in different units from low rumbling to loud knocks which result
heavy vibration o f the unit. The required acceleration o f water to the high velocity is suddenly filling the hollow spaces is
a loss and cavitations w i l l therefore be accompanied by a reduced efficiency.

Cavitations w i l l occur mainly at the vane inlet portion o f the pump impeller on both the vanes and the sidewalk.
The erosion and wear due to cavitations w i l l not occur at the point o f lowest pressure where the gas pockets are formed
but they occur at the point o f further upstream.

To prevent cavitations, the suction pressure must be kept above the critical pressure at which it starts. Beside
this ,the followings are some o f the measures against the formation o f cavitations.

• Velocity o f fluid in the suction line should be low.

• A v o i d sharp bends to keep the friction and turbulence losses at a minimum.
• Keep the temperature o f the fluid at the minimum level.
• Specific speed o f fluid in the inlet side should be kept at low level.
• I f the thickness o f inlet vane is small, smooth and the inlet edges are in aerofoil shape, cavitations formation
will be low.
• There should be enough amount o f vanes in the impeller for efficient guidance o f water/liquid and also for
lowering down the pressure o f the fluid.

• Noise and erosion may be reduced i f a small but optimum quantity o f air is inserted into the suction side.

Qtiestion-1
A turbine pump discharges 2100 1/min with a total head o f 200 m. I f pump efficiency is 70%, motor efficiency
is 90%. Calculate the power required. (Second Class (restricted), 1984)
298 Surface M i n i n g Technology

Solution

2100 l/min = 35 I As

Disch arg e{—)xHead (in)

Power requirement = l _ i _ = 35.v200 = l08.93kW
1 ()2xefficiency.of pumpxmotor efficiency 102.v0.9.rf).7

Qiicstion-2

Calculate the electrical power required to lift 2000 1 o f water per minute to a height o f 240 m. Assume pump
efficiency as 0.75 and motor efficiency as 0.90. (Second Class (restricted), 1986)

Solution

2000 l/minute =33.33 l/s

Power requirement = 33.33.v240 _ j 1 6 l g k W

102,v0.75.v0.9

Reciprocating Pump (Fig. 10.4)

In this type o f pump a piston moves to and fro by a prime mover inside a cylinder which consists o f an inlet and
outlel port attached with the valve mechanism. In single stage reciprocating pump by each revolution o f Ihe prime mover
Ihe piston sucks water/liquid through the inlet valve by the backward stroke, compresses it from initial lo the final
pressure by the forward stroke and finally delivers it through the outlet valve in a single cylinder only. During ihe
backward stroke a vacuum w i l l be created inside the cylinders which w i l l initiates to force water to fill the vacuum by
opening Ihe inlet valve. A reciprocating pump basically consist o f a piston, cylinder, suction and delivery valves, suction
pipe and delivery pipe, etc.

VALVE
<—SUCTION RANGE

Fig. 10.4 : A Schematic Line Diagram o f a Reciprocating Pump.

T r i p l e Plunger P u m p

In consist o f 3 single acting plunger pumps driven by crosshead pistons which are operated through the
connecting rods by the crankshaft. The connecting rods are staggered by 120° on the crankshaft. Each pump consists o f a
plunger, a plunger case, suction and delivery valves, gland, stuffing box, etc. Water fluid passes through the suction
channel to the suction valve and thereafter fills the high pressure plunger case. The pressurized fluid produced by the
compression strokes o f the plunger. Water fluid there after is fed through the pressure valves via the pressure channel
into the pressure control device located at the upstream o f the delivery line or directly fed into the delivery line.
Reduction gear and crankshaft have a common oil chamber and the pump has pressure lubrication. The attachments and
accessories which are attached with a reciprocating pump consists o f a foot valve attached at the front end o f the suction
pipe, main valve at the delivery pipe range, retaining valve above the main valve and also the bypass valve for side
tracking main and retaining valve, air cock, air vessel, etc.
 Water in the Surface Mines and Mine Pumps

Advantages and disadvantages of a reciprocating pump

Advantages

A reciprocating pump offers the following main advantages :

• It is very much suitable to develop a very high pressure.

• It has larger life, uniform higher efficiency, simple, lower power cost, more reliable, lower operating cost as
compared to a centrifugal pump.
• Lower speed causes less wear in the components o f the pump and also can be applied under adverse and
variable pressure condition.
• l l does not require any priming
• A l l the internal parts are very much accessible and also less trained manpower is necessary in this system.
• l l can be used to handle muddy water for high head (a head o f 700m is very common) and low capacity. It is
efficiently used in the power pack systems.

Disadvantages

It has many disadvantages which are as follows

• l l produces pulsating output. Motors/prime movers withstand more pulsations and shock loads.
• Initial purchasing cost, maintenance cost, etc. are higher as compared to a centrifugal pump.
• Velocity in the suction range depends upon the speed o f the pump.
• The pump is bulky, heavier in weight, produces heavy vibration, noise and very complicated in construction
with heavy amount o f parts and components,
• It requires more space, requires robust and costly foundation to install and also installation is not very easy
• lis operating characteristics are not very much flexible in nature.

Starting and stopping of the pump

After opening the main valve start pump and during stopping first switch o f f motor and thereafter close Ihe main
valve. After a longer stoppage i f pump is to be restarted a little bit priming w i l l yield better result.

Submersible Pumps (Fig. 10.5)

The pump is a machine which can suck water up from a certain level and then deliver it under pressure where it
is required to be used. This was accepted despite the fact that the height from which it can suck water is strictly limited
by fundamental principles o f hydraulics irrespective o f the power o f the machine. Latter a novel form o f pump appeared
in ihe market and this was designed to run under submerged conditions in the water eliminating the need for suction
entyrely thus greatly enhances the efficiency o f the operation. Unfortunately this means that a long vertical shall was
required running down ihe well from the motor situated above ground. The motor had to be carefully mounted and
housed and the shaft is carefully lined up and carried in bearings in the well which is quite an expensive set up. The
submersible motor idea revolutionary. I t consists o f a pump close coupled to a motor, the whole assembly being capable
of submerge into water to almost at any depth.
300 Surface M i n i n g Technology

HANDLE

Fig. 10.5 : A Schematic Line Diagram o f a Submersible Pump.

B r i e f Description

A brief description o f the basic design is given below:

Pumps
The submersible pump basically comprises o f a number o f impellers mounted in a shaft, supported by journal
bearings and the impellers are housed in suitable casings fitted with guide and return vanes. The pumped liquid/water
enters into the first or lower most impeller and is passed progressively through the unit with an increase o f head at each
impeller stage and finally discharges into the raising main pipe work.

Submersible motors
Submersible motors are o f the induction type, falling into two categories those using windings which are
directly submerged in water generally referred to as wet motors and those which use the conventional dry motor winding,
being hermitically sealed from the surrounding liquid.

Dry motor
Here conventional dry windings are used and these are sealed within a suitable casing. The inner tube o f which
is non-magnetic one which separates the stator from the rotor unit and is only a few thousands o f a centimeter thick. The
stator of a dry machine is usually filled with resin to aid heat dissipation. Pumps are generally made o f aluminum, cast
iron, stainless steel, gun metal, etc, and may be externally coated with chlorinated rubber point. The motor is totally
enclosed, steel construction and in some version stator is designed to withstand, temperature up to 155° C. Three thermal
protectors are connected in series in stator winding, one in each phase. These break the control circuit to the pump motor
contactor i f the temperature o f the winding exceeds the stipulated temperature. Double mechanical face seals are
provided with intermediate o i l casing manufactured from carbon/tungsten carbide material. Motor has the PVC insulated
 Water in the Surface Mines and Mine Pumps 301

winding having PVC insulated power cable which is connected in the double sealed cable entry, although in some cases
particularly in case o f FLP submersible pump, power cables are factory mounted. There is a inspection cover on the top
junction box for checking the electrical wiring.

Advantages

The main advantages o f the submersible pumps are as follows :

• Submersible pumps are highly efficient for a small quantity o f discharge,
• Does not require any housing for installation,
• Require very less space, very easy to install and withdraw,
• Very little supervision is required for maintenance,
• There is very less chance o f explosion due to fire since pump is totally submerged into water,
• It does not require any priming,
• The impeller and diffuser are both adjustable for obtaining the optimum efficiency,
• It can be operated at any orientation and also automatic operation is generally practiced.

But ihe cable for a submersible pump is very expensive, it can be used efficiently to pump out clean water and
also its working is not visible.

Common range o f submersible pumps generally have power ranging from 0.9 k W to 425 kW having a
discharge capacity varying from 251/s to 5000 1/s with an average lift varying from 20m to 200m although a lift o f around
300 in is not uncommon. Submersible pumps are also available to discharge a quantity o f more than 7000 l/s. formed b\
the' diaphragm which are connected in the inner periphery o f the outer casing. Table 10.3 shows the characteristics o f
some of the submersible pumps.

T a b l e : 10.3 Submersible pump characteristics

Head Allowable submergence Best range

(m) (%)
38-54 40-65 60-65
>54-75 40-60 55-60
> 7 5 - l 10 37-55 50-55
195-230 35-45 40-45

P O W E N pump factory o f Poland manufactures many types o f submersible pumps out o f which P-Series is wonh to
mention. These pumps are centrifugal and single stage . W i t h these pumps there is possibility o f operation in
submergence up to 6m deep, and also operation with self-sealing catch and tracks operation with liquid level sensors,
elc. are possible Thermal protection o f motor winding is incorporated in these type o f pumps. Table 10.4 shows the
specification o f various pumps under this series.

Table -10.4 Some submersible pumps manufactured by the P O W E N pump factory o f Poland

Type Capacity Head Max. solid size r.p.m Power

(m'Vh) (m) (mm) kW
P30-F65/4A 50 13 28 1410 3.7
P55-K100/4A 100 13.5 75 1420 8.3
P110-Z125/4A 150 14.5 65 1455 11.3

Roto Pump (Fig. 10.6)

A roto pump (mono pump) basically operated on screwing action. .It is basically a single eccentric screw pump.
It consist o f a single helical monel /nitralloy/ N i - C r /stainless steel eccentric rotor unit placed inside the stationary torsion
free bonded rubber/hypalon /other plastic material made stator. The rubber stator is placed inside a C.I/M.S. housing.
302 Surface M i n i n g Technology

Pilch of Ihe stator is half Ihe pitch o f a rotor unit and hence when rotor rotates inside the slalor unit a constant seal starts
advancing along with the entrapped water in it's front (from suction to the delivery side) uniformly. During rotating of
the rotor, because o f the exhaust created by the rotor and stator mechanism in the space in between them, all air exhaust
out and water is filled up and caught in it's place by high suction. The trapped water thereafter moves forward as the rotor
rotates and forced out through the outlet o f the roto pump. The pumps are non-clogging and self priming type. Roto
pumps are electrically driven, generally used for small capacity pumping varying from 0.5 m /hour to 120 m /hour ai a
3

pressure varying from 2.8 kg/cm" lo 24 kg/cm". But a head o f about 90 m is also not uncommon. Generally i f the water is
muddy and gritty . this type o f pumps are very suitable. A snore by-pass is attached with the pump system which
reticulates a very liltle quantity o f water through the pump when there is no water in the sump and also i i keeps the slalor
and rotor lubricated. The speed o f the rotor is kept low (say in between 960rpm to 1450 rpm) and also the velocity o f
water/liquid inside the pump is very less. This helps lowering down the vibration, noise, wear in both the stator, rotor and
oilier movable units. Roto pumps are very efficient as compared to centrifugal pump where high fluctuation of discharge
of water is needed. By changing the direction o f rotation the side o f the suction and discharge can be reversed. However
it should always be remembered that the diameter o f delivery pipe range should be smaller as compared to the suction
pipe range lo increase the velocity o f the water to combat suspension o f the solid particles. I f the pump is kepi running in
the dry condition then there w i l l be more wear in the stator unit due to the lack o f lubrication and the production o f more
heat. Sizes o f the solid particles present in the water should be sufficiently smaller in size so that they can be
accommodated in the helical spaces in between the stator and rotor. The driving shaft o f rotor is hollow in construction
which mounts over ball bearings and rotates by an electric motor via a fluid coupling and gearbox. The roto pump is of
skid mounted. Table 10.5 shows specification o f some o f the mono pumps.

Table : 10.5 Specification o f some o f the mono pumps

Capacity Power Head rpm Type

(mVh) (kW) (m)
10.60 1.65 50 600 LL-1
22.30 8.3 50 1200
17.4 2.3 50 400 LM-1
36.8 5.5 50 800

Fig. 10.6 : A Schematic Line Diagram o f a Mono Pump (Roto Pump).