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Newmont Cadia relies on Weir GEHO TZPM 1200 positive displacement piston diaphragm pumps to dewater its 1.4 km deep underground mine. These pumps, located 1.1 km below the surface, are critical to the mine’s operations. If a pump fails, the mine could flood within four days, making precise and reliable maintenance essential.
WMS specialises in the precision maintenance and repair of these high-volume, high-pressure pumps. The pump system at Newmont Cadia consists of an electric motor driving a high-reduction gearbox and three-cylinder, single-acting piston diaphragm pumps. The mine had experienced recurring issues with this setup, including hot motor bearings, frequent motor bearing failures, and gearbox input shaft bearing failures. A gearbox overhaul following failure typically costs the mine $125,000, while a full replacement assembly is $250,000, creating a strong financial incentive to resolve these issues.
WMS was commissioned to conduct an annual service, replace the gearbox following a failure, and recommission the system. Using the XT770 GEO alignment system, they assessed the alignment of the motor and gearbox assembly before starting repairs. The alignment check revealed a severe angular misalignment (approximately 1.8 mm at the gearbox feet) in the vertical plane, likely from previous maintenance work. This misalignment was identified as the probable cause of the hot motor bearings and the repeated motor and gearbox bearing failures.
After removing the old gearbox, WMS used the XT770 GEO’s geometric functions to verify the flatness and distortion of the foundation prior to installing the replacement gearbox. They then employed the XT770 GEO to achieve precise alignment of the entire machine train from motor to gearbox and gearbox to pump, ensuring optimal performance.
The precision maintenance and alignment carried out by WMS have enabled the pump system to operate reliably for over 12 months, with no recurrence of motor or gearbox bearing failures. This stable operation has minimised costly downtime and safeguarded the mine’s essential dewatering process, emphasising the value of WMS’s expertise and the capabilities of the XT770 GEO system at Newmont Cadia.
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