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An easy-to-understand introduction to
slurry pumps and systems

This is the shell or

volute of a very large
slurry pump.

Readers Guide

For Our Customers

Past, Present and Future

Editor & Designer Mary A. Sicard

Project Editor Thomas Mueller
Production Controller Pam Welty
Tech Team Bob Courtwright,
Tom Wujcik, Richard Inglett,
Reab Berry and Kevin Kuehne

Copyright 2006
GIW Industries Inc./KSB Mining
Group

All rights reserved. No part of this publication may be

reproduced, stored in a retrieval system or transmitted
in any form or by any means, electronic, mechanic,
photocopy, recording or otherwise, without the prior
written permission of the copyright owner.

Meet Digsby. He
appears
whenever we want
to give you a
mountain of
information
but only
have room for
a mole hill. He tells you where to dig
deeper in other sources and in the
textbook, Slurry Transport Using
Centrifugal Pumps, written by Drs.
Kenneth C. Wilson, Anders Sellgren
Roland Clift and GIWs VP of
Engineering Graeme Addie. The
textbook is available from Kluwer
Publishing (www.wkap.nl).

giwindustries.com
Does your slurry have an attitude? Is it
caustic? Corrosive? Abrasive? Erosive?
(Or some combination thereof?) If so,
talk to us. We can make the biggest,
baddest, meanest, nastiest slurry
behave. We are the experts in slurry
transport, so challenge us to solve your
production delays or to improve your
slurry pumping systems.

Get in touch and

stay in touch
5000 Wrightsboro Rd. Grovetown, Ga. 30813
Phone: 706.863.1011 Fax: 706.863.5637

A KSB Company

1.888.TECH.GIW (832.4449)
sales@giwindustries.com

Slurry Pump Fundamentals

Contents
Chapter 1: What Is Slurry? .......................................................... 9
Slurry Pumps vs. Water Pumps ....................................................................... 9
Flow Limitations ....................................................................................... 10
Solids Limitations ...................................................................................... 11

Chapter 2: Slurry Pumps Defined ............................................... 13

Markets & Applications for Slurry Pumps ......................................................... 14
Installations ............................................................................................. 14
DRY ............................................................................................................................. 15
SEMI DRY ....................................................................................................................... 15
WET ............................................................................................................................ 15

Wear Conditions ....................................................................................... 15

Chapter 3: Slurry Pump Design & Components ............................... 17

Basic Designs............................................................................................ 17
Basic Components ..................................................................................... 17
Impeller .................................................................................................. 18
CLOSED IMPELLERS .......................................................................................................... 18
OPEN IMPELLERS ............................................................................................................. 18

Vane Designs ............................................................................................ 19

Shell ...................................................................................................... 19
SHELL TYPES .................................................................................................................. 19
SPLIT AND SOLID SHELLS ............................................................................................. 19

Suction Liner ........................................................................................... 20

Shaft Seals .............................................................................................. 20
STUFFING BOX ................................................................................................................ 20
MECHANICAL SEAL ........................................................................................................... 20
EXPELLER ..................................................................................................................... 20

Shaft and Bearings ..................................................................................... 21

SHAFT .......................................................................................................................... 21
BEARINGS ...................................................................................................................... 21

Drives for Slurry Pumps .............................................................................. 21

BELT DRIVES .................................................................................................................. 21
GEARBOX DRIVES ............................................................................................................ 21
DIRECT DRIVES ............................................................................................................... 21

Chapter 4: Wear Protection ...................................................... 23

Wear ...................................................................................................... 23
Corbrasion ............................................................................................. 23

Selection of Wear Materials ......................................................................... 23

HARD METAL CONSTRUCTION ............................................................................................. 24
WHITE IRONS ........................................................................................................... 24
STEELS ................................................................................................................... 24

Elastomer Construction .............................................................................. 25

Ceramic Wear Parts ................................................................................... 25
Corrosion Resistance and Wear Resistance ....................................................... 25
Wear Resistance Range ............................................................................... 26
pH Ranges ............................................................................................... 27

Chapter 5: Hydraulics .............................................................. 29

Pumps and Curves ..................................................................................... 29
PERFORMANCE CURVE ...................................................................................................... 30
SYSTEM CURVE ............................................................................................................... 31
THE INTERSECTION .......................................................................................................... 32

Head ...................................................................................................... 32
NET POSITIVE SUCTION HEAD (NPSH) .................................................................................... 32

Vapor Pressure and Cavitation ...................................................................... 33

CAVITATION ................................................................................................................... 33
NPSHR .......................................................................................................................... 34
NPSHA .......................................................................................................................... 35
CAUSES OF CAVITATION ..................................................................................................... 35
HOW TO FIND THE CAUSE .................................................................................................. 36
TO AVOID CAVITATION ...................................................................................................... 36

Pumping Froth.......................................................................................... 36

Chapter 6: Slurry Pump Systems ................................................ 37

Overview ................................................................................................ 37
Pipe Systems ............................................................................................ 37
Friction Losses ......................................................................................... 39
STRAIGHT PIPES .............................................................................................................. 39
FITTINGS ....................................................................................................................... 40
SLURRY EFFECTS ON FRICTION LOSSES ................................................................................. 40
FRICTION LOSSES IN SETTLING SLURRIES ............................................................................... 40
NOMOGRAM FOR DETERMINING DEPOSIT VELOCITY ............................................................ 41
FRICTION LOSSES IN NON-SETTLING SLURRIES ......................................................................... 42

Viscosity ................................................................................................. 42
NEWTONIAN AND NON-NEWTONIAN LIQUIDS ........................................................................... 42
OTHER NON-NEWTONIAN FLUIDS ......................................................................................... 43

Sump Arrangements ................................................................................... 43

Multiple Pump Installations .......................................................................... 44
PUMPS IN A SERIES ........................................................................................................... 44
PUMPS IN PARALLEL ......................................................................................................... 45

Slysel ..................................................................................................... 45

Chapter 7: Best Efficiency Point ................................................. 47

Optimal Efficiency ..................................................................................... 47
Radial Load .............................................................................................. 47
Axial Load ............................................................................................... 48

Slurry Pump Fundamentals

Shaft Deflection ........................................................................................ 49

Water Hammer ......................................................................................... 49

Chapter 8: Technical Descriptions .............................................. 51

Metal Pumps ............................................................................................ 51
LCC METAL SERIES (LCC-M) ................................................................................................ 51
FEATURES ............................................................................................................... 52
APPLICATION ........................................................................................................... 52
SIZE RANGE ............................................................................................................. 52
LSA-S SERIES .................................................................................................................. 52
FEATURES ............................................................................................................... 52
APPLICATION ........................................................................................................... 53
SIZE RANGE ............................................................................................................. 53

Rubber Pumps .......................................................................................... 53

LCC RUBBER-LINED SERIES (LCC-R) ....................................................................................... 53
FEATURES ............................................................................................................... 54
APPLICATION ........................................................................................................... 54
SIZE RANGE ............................................................................................................. 54
LSR HEAVY-DUTY RUBBER-LINED SERIES ................................................................................ 54
FEATURES ............................................................................................................... 54
APPLICATION ........................................................................................................... 55
SIZE RANGE ............................................................................................................. 55

Vertical Pumps ......................................................................................... 55

LCV SERIES .................................................................................................................... 55
FEATURES ............................................................................................................... 55
APPLICATIONS .......................................................................................................... 56
SIZE RANGE ............................................................................................................. 56

High-Pressure, Multi-Stage Slurry pumps ......................................................... 56

WBC ............................................................................................................................ 56
FEATURES ............................................................................................................... 56
APPLICATIONS .......................................................................................................... 56
SIZE RANGE ............................................................................................................. 56
TBC ............................................................................................................................. 57
FEATURES ............................................................................................................... 57
APPLICATIONS .......................................................................................................... 57
SIZE RANGE ............................................................................................................. 58

Flue Gas Desulfurization Pumps (FGD) ............................................................ 58

FEATURES ............................................................................................................... 58
APPLICATION ........................................................................................................... 58
SIZE RANGE ............................................................................................................. 58

Chapter 9: Application Guide .................................................... 61

Selection by Duty ...................................................................................... 61
CLASSIFYING SLURRY ........................................................................................................ 61
GIWS SERVICE CLASS CHART .............................................................................................. 62
GIWS OPERATING LIMITS CHART ......................................................................................... 62

Guidelines for Selection by Duty ................................................................... 63

COARSE PARTICLES .......................................................................................................... 63
FINE PARTICLES .............................................................................................................. 63
SHARP (ABRASIVE) PARTICLES ............................................................................................. 63
HIGH PERCENT SOLIDS ...................................................................................................... 63
LOW PERCENT SOLIDS ...................................................................................................... 63
FIBROUS PARTICLES ......................................................................................................... 63

Duties Related to Head and Volume ............................................................... 64

HIGH HEAD .................................................................................................................... 64

VARYING HEAD AT CONSTANT FLOW ..................................................................................... 64
VARYING FLOW AT CONSTANT HEAD ..................................................................................... 64
HIGH SUCTION LIFT .......................................................................................................... 64
HIGH FLOW ................................................................................................................... 64
LOW FLOW .................................................................................................................... 64
FLUCTUATING FLOW ........................................................................................................ 65

Duties Related to Slurry Type ....................................................................... 65

FRAGILE SLURRIES ........................................................................................................... 65
HYDROCARBON SLURRIES (OIL AND REAGENTS CONTAMINATED) ................................................... 65
HIGH TEMPERATURES ABOVE 212F (100C) SLURRIES .............................................................. 65
HAZARDOUS SLURRIES ...................................................................................................... 65
CORROSIVE SLURRIES (LOW PH) .......................................................................................... 65
HIGH VISCOSITY FLUIDS (NEWTONIAN) .................................................................................. 66
HIGH VISCOSITY FLUIDS (NON-NEWTONIAN) ............................................................................ 66

Selection by Industrial Application ................................................................. 66

HARD ROCK MINING ......................................................................................................... 67
OIL SANDS ..................................................................................................................... 67
PHOSPHATE ................................................................................................................... 67
FGD ............................................................................................................................. 67
INDUSTRIAL PROCESS ....................................................................................................... 67

Chapter 10: Computerized Pump Selection ................................... 69

Slysel ..................................................................................................... 69
SOFTWARE AND HARDWARE REQUIREMENTS ........................................................................... 70
ORDER INFORMATION ....................................................................................................... 70

Chapter 11: General Maintenance .............................................. 71

Maintenance ............................................................................................ 71
RECOMMENDED MAINTENANCE SCHEDULE .............................................................................. 71
DAILY ........................................................................................................................... 71
WEEKLY ........................................................................................................................ 72
QUARTERLY ................................................................................................................... 72
SEMI-ANNUALLY .............................................................................................................. 72

Impeller Removal ...................................................................................... 72

IMPELLER BALANCING ....................................................................................................... 73

Fastener Torque ........................................................................................ 74

TORQUE ACCURACY ......................................................................................................... 74
TORQUE CHARTS ....................................................................................................... 74

Mechanical Seals ....................................................................................... 74

Bearing Temperatures ................................................................................ 75
LUBRICATION OIL OR GREASE? .......................................................................................... 76
CAUSES OF BEARING FAILURES ............................................................................................ 77

Vents and Breathers ................................................................................... 78

Chapter 12: Total Cost of Ownership ........................................... 81

Importance of Making Smart Pump Purchases ................................................... 81
How GIW Can Help ..................................................................................... 82
Predicting Wear ........................................................................................ 82
Calculating Energy Costs ............................................................................. 83

Slurry Pump Fundamentals

Chapter 13: Troubleshooting ..................................................... 85

Why Isnt My Pump Pumping Correctly? .......................................................... 85
Warnings ................................................................................................. 85
EXCESSIVE PUMP DISCHARGE PRESSURE .......................................................................... 85
EXCESSIVE LEAKAGE AT SHAFT SEAL .............................................................................. 85
PUMP DELIVERS INSUFFICIENT FLOW RATE ....................................................................... 85
INCREASE IN BEARING TEMPERATURE .............................................................................. 86
BEARING CONTAMINATION ........................................................................................... 86
HIGH TEMPERATURE OR LEAKAGE AT THE STUFFING BOX ..................................................... 86
OVERHEATING OF PUMP CASING .................................................................................... 87
PUMP CASING LEAKS .................................................................................................. 87
PUMP FLANGE LEAKS ................................................................................................. 87
MOTOR OVERLOAD .................................................................................................... 87
VIBRATIONS OR ABNORMAL NOISES ................................................................................ 88

Help Is Here ............................................................................................. 88

Chapter 14: Appendix ............................................................. 91

Temperature Conversion Chart ..................................................................... 91
Mass Conversion Chart ................................................................................ 91
Velocity Conversion Chart ........................................................................... 91
Flow Conversion Chart ............................................................................... 92
Volume Conversion Chart ............................................................................ 92
Length and Distance Conversion Chart ............................................................ 93
Pump Duty Information Sheet ....................................................................... 94

Chapter 15: Glossary ............................................................... 95

Chapter 16: References ......................................................... 101

Chapter 17: Where It All Comes Together ................................... 103
Capabilities ........................................................................................... 103
TESTING AND DEVELOPMENT ............................................................................................
DESIGN ENGINEERING .....................................................................................................
MANUFACTURING ..........................................................................................................
PRODUCTS ...................................................................................................................

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103
104
104

History ................................................................................................. 105

Parent Company ..................................................................................... 105
How To Contact GIW ................................................................................. 106
GIW INDUSTRIES ............................................................................................................
SERVICE CENTERS ..........................................................................................................
GIW REGEN SERVICE CENTER ......................................................................................
GIW FLORIDA SERVICE CENTER ...................................................................................
FT. MCMURRAY SERVICE CENTER .................................................................................

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Chapter 1: What Is Slurry?

Chapter 1:

What Is Slurry?
Slurry is a mixture of something solid and a liquid.
The solids in a slurry can be anything from gold to gravel,
copper to coal, sand to cement. They can also be crystalline,
sharp, flaky, fibrous or frothy.
Almost any solid can be transported hydraulically via a slurry
pipeline using a slurry pump.
Clear water is the primary liquid for slurry transport,
but other liquids such as acids, alcohol and light
petroleum have been used.
In the mining industry, slurry pumps are used to transport
slurries. The production of fertilizer, for example, involves
massive slurry transport operations. To make the fertilizer,
phosphate matrix is recovered by draglines in open-pit mining
operations. (Draglines are huge electrically powered excavating
machines with buckets that hold as much as 150 tons.) The
matrix is then slurried (mixed with water) and pumped to the
wash plant through pipelines with a typical length of six to 10
miles.

See Applications of Slurry Transport in Slurry Transport

Using Centrifugal Pumps.

Slurry Pumps vs. Water Pumps

Slurry pumps can be massive and often have replaceable wear parts. They are
usually much heavier and larger than clear water pumps sized for the same
head and flow. Some of the reasons for their larger size are:

10

Slurry Pump Fundamentals

Slurry pumps are constructed of special materials because of the abrasive

nature of most slurries.
These materials often
require special bolting and
assembly arrangements.
Slurry pump components
are normally thicker than
components for water
pumps.
Slurry pump shafts and
bearings are often larger
than those on water
pumps, because slurry
Slurry pumps, like the one shown above,
pumps handle various
are usually much larger than water pumps.
sizes and concentrations of
solids.
Slurry pumps require larger impeller diameters to produce the same
head because they usually run slower than water pumps to keep the
wear within reasonable limits.
Slurry pumps may have large internal passageways because they often
pass large solids.
Water pumps account for the largest percentage of pumps installed in the
process industry. For every five slurry pumps, 95 water pumps are in operation.
The purchase and operating costs of a slurry pump are often many times that
of a standard water pump. (Some industry experts put the operating costs of
slurry pumps compared to those of water pumps at 80:20.) This is why the
correct selection and application of your slurry pump is essential to your
operations efficiency.

Flow Limitations
The flow limitations for a slurry pump installation are from 35 - 132,000 gpm
(8 - 30000 m3/hour).

Chapter 1: What Is Slurry?

These limits are determined by the pumps ability to withstand the forces
associated with operating the pump, such as pressure, vibration, axial thrust
and the stability of the pump at various flows.

See Basic Relations for Flow of Simple Fluids in Slurry Transport Using
Centrifugal Pumps.

Solids Limitations
Theoretically, there are no limits on what can be hydrotransported. In practice, however, the size and shape of the solids limit what can be pumped
because of the risk of
the solids blocking
passage through the
pump.
The maximum
particle size of
material that can be
transported in a
slurry pump is
approximately 12
inches (300 mm).
However, sphere
passage in large
dredge pumps can
be up to 18 inches
(450 mm).

The solids transported in this dredging operation were

as large as a hard hat.

See Basic Relations for Slurry Flow in Slurry Transport Using

Centrifugal Pumps.

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