Guidelines for slurry pumping - pumpfundamentals.com

1 slurry handbookGuidelines for slurry pumpingSlurryA mixture of solids and liquid,generally water. The particlesmay not be abrasive althoughthis is of contents1. Introduction ..4 slurry pumps .. 5 Applications .. 5 slurry pump types .. 62. Flygt slurry pumps ..8 Drive unit .. 9 Hydraulic design .. 133. slurry properties ..15 slurry parameters .. 16 slurry characteristics .. 18 Liquid definitions .. 204. slurry pump systems ..21 Pump performance .. 21 Calculating with FLYPS .. 22 System design .. 23 Sizing the pump .. 25 Other considerations .. 265. Application guide ..30 Types of installation .. 30 Application areas .. 316. Appendix ..36 Step by step calculation .. 36 Index .. 45 Designations and formulas .. 46 slurry questionnaire .. 4741. IntroductionFLYPSF lygt s pump selectionprogram is now availablewith a slurry modulewhich makes it possible tomake pump selectionbased on liquid containingsolid particles.

2 Where are slurry pumps used? Can submersible slurry pumps replace other typesof pumps? Which parts are of special importance in asubmersible slurry pump? How can slurries be classified? Which parameters of the slurry and pipe systemare required to be able to dimension a pumpcorrectly?The purpose of this book is, in a simple way, todescribe slurry pumps, slurry pumping and the variousparameters required when selecting submersible slurrypumps using provide a deeper understanding of the calculations,a manual calculation example is given in the appen-dix of the you are not sure about the type of slurry , the choiceof pump, the design of the pipe system, etc., youcan always contact your Flygt support for pumpsSlurry pumps are a heavy and robust version of cen-trifugal pumps, capable of handling tough andabrasive pumps should also be considered a genericterm, to distinguish them from other centrifugalpumps mainly intended for clear pumps are used to move mixtures of liquidand solids in many industries with a broad spectrumof applications, for example mine drainage,dredging of settling lagoons and pumping of dril-ling purpose can be: To pump a medium where abrasive particlesare present To transport as much solids as possible,hydraulically To pump the end product in a processFlygt submersible pumps are used in many diffe-rent industrial segments like.

3 Iron and steel Power generation Pulp and paper Oil and gas Waste water treatment Mining Mineral processing ConstructionChapter 5 gives a brief overview of some commonindustries and applications for slurry pump typesThree main types of pumps are used for slurrypumping: Horizontal slurry pumps Vertical slurry pumps Submersible slurry slurry pumpsThese types of pumps are often called dry mountedas the hydraulic end and the drive unit are locatedoutside the sump. It is the main group of slurrypumps and they are available for a wide range ofhead and flow conditions and material types of pumps normally use standardizedelectrical motors and plants where there is a risk of flooding, there canbe reasons for replacing a horizontal pump by a dry-mounted, submersible, slurry slurry pumpsThis type of pump can be subdivided into two maingroups: Tank pumps Cantilever/sump pumpsTank pumps are considered as dry installed sump is incorporated in the pump.

4 Open sumpand vertical inlet prevent air blocking and givesmooth operation. There are no submergedbearings or shaft seals, but quite a long shaft over-hang from lower bearing to the outletinletoutlet7 All the information thatfollows in this book, suchas technical descriptions,calculation examples, etc.,is applicable to sub-mersible slurry pumps are considered as semi-dryinstalled, as the hydraulic end is lowered into the slurry ,but the drive unit and support structure are dry to tank pumps there are no submerged bearingsor shaft seals, but a long shaft on size the pump is either mounted witha base plate over the sump or hung from the have a number of disadvantageswhich make them suitable for replacement withsubmersible pumps: Long distance between motor and volute makesthe pump bulky to handle. Limited access to the sump. Problems with sedimentbuild-up when used in sumps deeper than 2 m.

5 Not water-proof. Flooding will damage themotor. High noise submersible?Some slurry pump users may have limited knowledgeof submersible slurry pumps. It is therefore importantto advance arguments for the submersible pumps offer a number of benefits overdry and especially semi-dry mounted pumps: Operating directly in the slurry , the submersibleslurry pump requires no support structure. Ittherefore occupies less space. The motor and volute are one integrated unit,compact and easy to install. Operation underwater means low noise levels oreven silent operation. Motor cooled by surrounding liquid allows for upto 15 starts/hour, resulting in smaller and moreefficient sumps. Flexible installation with several installation modes,all of which are either portable or semi-permanent. Possibility to practice Clean sump technology(see page 28).inletoutlet82. Flygt slurry pumpsThe main difference between slurry and waste waterpumps is in the parts that are in direct contact withthe slurry and thus subject to wear by the slurry ssolid factors for slurry pumps such as cooling,seals and especially the hydraulic design, aredescribed in this submersible pumpequipped with agitatorCooling jacketInspection chamberSealStrainerAgitatorMotorImpeller Stand9 Standard motordesignFlygt motordesignDrive unitMotorImportant factors for slurry pump motors: Effective cooling InsulationEffective coolingWater cooling is superior to air cooling and givesthe submerged motor a high power density andcomparatively low the Flygt motor the rotor diameter is bigger andthe stator thinner than in standard motors.

6 Thisdirects more of the losses (heat release) to the sta-tor and to the surrounding, cooling liquid. The shortheat transfer distance makes the cooling effectiveand keeps the working temperature pump can be cooled in three ways dependingon the slurry temperature and other circumstances:1. Pumps that work fully submerged in slurry , cooledby the ambient liquid. The slurry temperature maynot exceed 40 Pumps that work at times with the motor partiallyor totally un-submerged, can be equipped with acooling jacket for internal cooling, where a coolingmedium (glycol mixture) circulates (5100/5150).3. Pumps that often work in a low level, in hot slurryor are dry installed can be cooled using an externalsupply of cooling liquid, connected to the ways in which the various cooling methods areused is described on page with internalcooling system10 Pump shaft andbearingsInsulationClass H insulation (180 C) is applied to the statorwinding by a trickle impregnation system.

7 Flygtlimits the motors to Class B rise (140 ), whichreduces thermal stress resulting in extended impregnation gives a winding fill much greaterthan typical dip and bake systems. This gives muchhigher protection against short circuits in the and bearingsImportant factors for shafts and bearings: Shaft design and dimensioning Bearing type and protectionShaft design and dimensioningThe shaft and bearings are of sturdy design. Thedistance between the lower bearing and the impelleris minimal, eliminating shaft deflections. This prov-ides long seal and bearing life, low vibration andsilent type and protectionAll slurry pumps have two row angular contact ballbearings as the main bearing, because they give ahigh load capability in the radial as well as the bearings are well protected with a lifetimelubrication of high performance seal (5100/5150)SealsImportant factors for submersible pump seals: Low leakage and wear resistanceLow leakage and wear resistanceIn conjunction with low leakage rate, the mostimportant feature for seals in slurry applications isthe ability to resist wear from abrasive seals for the slurry pumps are designed to copewith highly abrasive pump media.

8 Only the seal ringsare exposed to the media. Other parts of the seal,such as springs and torque locks are protected fromwear, clogging and corrosion inside the seal pre-mounted Plug-in seal unit (5100/5150) isfast and easy to handle. The seal faces are closedand cannot be contaminated or damaged duringservice. The seal rings are always properly alignedto eliminate systemsImportant factors for submersible pumpprotection: The possibility of detecting a leaking seal before any damage occurs Spin-out seal protection Overheating protectionPossibility of detecting a leaking seal5500: In the area that contains cooling oil abovethe seal, there is a sensor that emits a warning ifwater enters. In addition, the oil is discoloured bywater leakage and this can be seen through aninspection screw on the side of the housing leakage: A float switch shuts thepump down if water is : The inspection chamber between theseal unit and the bearings has a built-in sensor forearly detection of fluid leakage.

9 The space can beinspected and emptied via a screw, which is easilyaccessible from the seal protectionA patented outer seal design that protects the sealby expelling abrasive protectionThermal sensors are embedded in the statorwindings to prevent chamber, 5100/5150 Spin-outTM sealprotection13 Standard hydraulic designFlygt hydraulic designHydraulic designImportant factors for submersible pumphydraulic parts: Efficiency Wear AgitatorEfficiencyPumping slurry can cause a severe reduction in thehydraulic efficiency of a pump. The Flygt impeller isdesigned to minimize this drop. Higher pumpingefficiencies also correlate with lower wear shows that the design of the impellerand volute is as important as the choice of mate-rial, in order to minimize the wear shape of the impeller used in slurry handling isimportant in ensuring high wear resistance andhydraulic efficiency.

10 The Flygt impeller has a moresweptback design than conventional impellers,which ensures a more homogenous flow betweenthe vanes. This minimizes the separation of solidsfrom the carrier liquid, resulting in extremely lowwear rates and sustained hydraulic pump impeller14 Because of the tangential outflow of particles fromthe impeller, suspended particles hit the volute wallat an almost parallel angle, thus decreasing linewear. The larger volute size also means a lowerinternal velocity, which further reduces the amountof trimmable impeller (5100/5150)/suction cover(5500) makes it possible to compensate for wearand thus prevent deteriorations in pump can be equipped with an agitator, desig-ned for maximum re-suspension of settled makes the particles easier to transport andensures a cleaner sump at the end of the use of the agitator is also described on slurry propertiesPumping slurry , a liquid containing solid particles,raises different requirements for a pump comparedto pumping just number of characteristics of the slurry and of thesystem must be known to be able to select a slurrypump selecting a slurry pump using FLYPS, Flygt sselection program for pumps, it is necessary to knowcertain parameters.