AISTech 2019 — Proceedings of the Iron & Steel Technology Conference

6–9 May 2019, Pittsburgh, Pa., USA

DOI 10.1000.377.153

Advanced Engineering Maximizes Efficiency and MTBR of Descaling Pumps

Ken Babusiak1, Bob Jennings2

1
HydroAire
2
Hydro, Inc.

BACKGROUND
A major steel plant had been experiencing catastrophic failures with their 5-stage descaling pumps for over four years. The
plant operated using three pumps online with two installed spares. All five pumps had a mean time between repair (MTBR)
of two years. The plant water quality is less than ideal, and the entrained abrasives were contributing to the repeated
premature failures.
In an effort to improve the pump operation, the end user reached out to both the OEM and several aftermarket repair shops
over the past five years with hopes for a more permanent solution to their pump problems. Maintenance records had indicated
that Hydro repaired one of their pumps several years ago and the pump had provided the longest runtime, operating over 4-
years without failure. Based on the extended runtime of the pump, the end user reached out to Hydro once more to assess the
situation and offer potential upgrades and high-quality repairs designed to increase the running time for all pumps in
operation.

THE CHALLENGES AND PROBLEMS ADDRESSED

Maintaining the internal clearances and the critical geometry of the impellers-to-diffuser fits are critical to maintain pump
performance and reliability. Erosion, caused by poor water quality, can lead to a number of pump reliability issues. When
pumping fluids that contain abrasive material, pumps can experience severe erosion and the effects can rapidly degrade both
the casings and impellers as well as the critical internal clearances.
While erosion itself isn’t always a difficult problem to solve, it’s important to have a good understanding of the relationship
between the type and location of the erosion and the metallurgy used in designing the pumps.

Figure 2 - Washout Leading To Increased Figure 2 Severe Erosion Leading To Component

Turbulence Instability

The forensic analysis of the pumps provided conclusive evidence that excessive clearances and geometric inconsistencies
with component fits were contributing to pump performance degradation outside of the abrasion issues alone.

© 2019 by the Association for Iron & Steel Technology. 1503

Analysis and action taken to overcome the issue
Hydro crafted a multilevel, comprehensive solution for resolving the multifaceted pumps leading to the premature pump
failures, beginning with a complete forensic analysis of the pump. Based on the extensive analysis, the root cause of failures
could be attributed hydraulic instability which occurred as the internal components degraded due, in part, to the erosion of the
critical clearances of the pump. The solution would involve both mechanical as well as hydraulic upgrades and
modifications.
Hydro began by completely cleaning, inspecting, and digitally mapping the pump casings and rotating components using
start-of-the-art laser scanning technology. The hydraulic design engineers then analyzed the impeller and volute geometry
and materials of construction. Based on their analysis, several improvements and upgrades were recommended.
The recommendation included:
• Manufacturing new impellers which would increase pump performance while providing higher efficiency and
greater hydraulic stability
• Upgrading from cast iron to cast steel bearing housings which would permit restoring and maintaining the critical
rotor alignment through the casing
• Upgrading the pump shaft material from steel (ASTM AS479) to forged (Type 410 Cond 2 Forged)
• The new impeller rings and casings rings were also upgraded to run “hard on hard” technology which provides
superior component durability that can greatly extend MTBF. The splitter on the bushings have also been upgraded
to provide a better interstage water flow, reducing internal hydraulic turbulence, which greatly reduced the vibration
level of the pump.
• Employ Laser Deposit Welding (LDW) procedure on the casing and impeller wear rings which would increase the
surface hardness and durability of the components without sacrificing the malleability of the base material (i.e.,
cracking due to brittleness).

State-of-the-Art Manufacturing Processes

In order to increase the mean time between repair of the pumps, Hydro provided several engineered upgrades including new,
high quality impellers which were designed to provide more stable hydraulic operation and were manufactured using latest
advanced mold technology (AMT).

Figure 5- 3D Foundry Sand Printer Figure 5- Advanced Mold Figure 5- Greater Dimensional
Technology Consistency

ATM produces far superior dimensional consistency and surface finish, which improves pump efficiency and operational
stability. The new impellers were designed to meet the flow and pressure requirements of the descale system while operating
allowing the pump to operate at higher efficiencies and thereby reducing the energy consumption.
Improper alignment of the bearing housings to the pump casing was discovered during the forensic analysis of the pump.
Over the years, repeated repairs to the cast iron bearing housings by “pad welding” had degraded the critical fits and
prevented accurate location of the housing-to-casing centerlines. By upgrading the bearing housing material to cast steel, the
proper fits were restored and would permit proper restoration of these components in the future.

1504 © 2019 by the Association for Iron & Steel Technology.

 Figure 7 – Old Style Bearing Housings Figure 7 - New Cast Steel Bearing Housings

Improved Component Durability

The water quality could not be improved, so the focus needed to shift to making the pump more resilient to the operating
conditions. Part of an engineered solution involves improving the durability of the pump components which in turn increases
the reliability of the pump.

The pump shaft material was upgraded from steel (ASTM AS479) to forged (Type 410 Cond 2 Forged) which provides
greater strength and improved rotor stability. The interstage bushings was also upgraded to provide a better interstage water
flow, reducing internal hydraulic turbulence, which greatly reduced the vibration level of the pump.
The new impeller rings and casings rings were also upgraded to run “hard on hard” using Laser Deposit Welding (LDW)
technology which provides superior component durability that can greatly extend MTBF. LDW is a process in which a metal
coating is applied (deposited) onto the surface of a part using a laser as the heat source. The process is often used to create a
protective coating for increased functionality, as well as restore damaged or worn surfaces. Laser cladding allows extended
life of equipment and machinery in which parts are exposed to erosion, wear, or impact.

© 2019 by the Association for Iron & Steel Technology. 1505

 Figure 9 - Laser Deposit Welding Procedure Figure 9- LWD Produces Greater Surface Hardness
The casing/impeller wear rings are considered sacrificial components which are designed to control the water in the high-
pressure discharge side of the impeller from “leaking” to the low-pressure suction side of the impeller. As the running
clearances of these components open up, greater leakage occurs, resulting in increased turbulence and rotor instability. When
handling fluids that contains abrasives, these critical fit and degrade very rapidly, leading to premature pump failure.
In the past, manufacturers heat-treated the wearing rings increase the surface hardness and extend the durability of these
components. However, heat-treating also causes the part to become brittle and it was not uncommon for the brittle wear rings
to crack during operation and cause catastrophic pump failures. By using the LWD process on the mating surfaces of the
wear rings, superior surface hardness is achieved and since LWD process does not affect the substrate, the wear ring is no
longer susceptible to cracking.
Field tests on LWD components have validated the benefits of this process, resulting in a) extended MTBR, and b) higher
average operating efficiencies.

Maintaining Pump Performance

The final component of this comprehensive repair was to provide the end user with a high-level field service team to remove
and re-install all the pumps on a turn key proposition.
What made this project unique was Hydro’s commitment to provide a long-term solution by providing a wireless condition
monitoring system which streams live vibration data to Hydro’s team of engineers who continuously monitor and evaluate
the data.

Figure 10 - Wireless Real Time Vibration Monitoring

Two pumps were actively in service, being monitored by ten magnetic wireless sensors measuring vibrations up to 20,000hz
with automated alerts and predictive reporting protocols.
When compared to traditional route-based data collection, wireless remote monitoring allows operators and engineers to see
real-time data and to make educated decisions regarding their assets. A wireless data collection system assists users to
identify issues before they escalate. In contrast, a route-based data acquisition strategy may miss these events depending on
the frequency of the route.

1506 © 2019 by the Association for Iron & Steel Technology.

 Figure 11a - Potential Failure to Failure Figure 12b- Maintenance / Repair Optimization

Figure 13- Savings of Conditioned Based Monitoring

The end user had been using “time-in-service” as the criteria for scheduling pumps to be sent out for repair. Based on the data
provided by the wireless condition monitoring system, the end user was able to determine which pump was showing signs of
the most depreciated performance and was able to send the pump out for much needed repairs ahead of schedule, and
averting a potential catastrophic failure resulting unplanned downtime and emergency repairs. This saved the customer well
over $100K in repair costs, not including the unplanned outages costs.

The benefits and success factors

The forensic analysis and customized engineered solutions resulted in a long-term solution to the customer’s pump problems.
The pumps are now operating with vastly improved mean time between repair (MTBR), reduced energy costs and the
continuous monitoring will assist in identifying future potential problems and will allow the mill to optimize their repairs
rather than reacting to catastrophic failures.
The plant had been sending the pumps to local pump shops who were replacing parts and restoring the pumps, but too often
simply repairing the pump does not identify and correct the root cause of the pump failures. The adage “If nothing changes,
nothing changes” applies to the repair approach. Degraded pump performance, coupled with repetitive failures requires a
more comprehensive, forensic engineering analysis (FEA) to identify and correct the problem.
As a result of solving the problem, coupled with the real-time, ongoing monitoring of the pumps, Hydro has become the sole-
source provider for all future repairs for the mill’s critical descaling pumps and equipment.
Poor water quality can lead to heavy erosion and hydraulic turbulence which can damage a pump. Understanding how a
pump functions in correlation to the material its pumping can offer the insight needed to assess the type of damage and
develop the best solution. Hydro was pleased to be able to provide the end user with a solution that promised them with not
only reliable pumps, but a guarantee of high quality and cost-effective service.

© 2019 by the Association for Iron & Steel Technology. 1507