Flowserve Caustic Sump
Application: Caustic Service for Steel Galvanizing
Pump Details: Flowserve 4x4x12 Model 4565
Pump Type: Single-Stage Vertical Sump
A steel galvanizing plant experienced decreased production when three vertical sump pumps in caustic service suffered consecutive failures. To meet production requirements, the plant was forced to rent submersible pumps until the vertical pumps could be repaired.
Hydro’s inspection revealed bearing failure, impeller vane wear, and damage to the shafts and columns. These failure modes had been caused by a lack of lubrication, which resulted in the shaft eating through the bearing into the column of the pump.
Many new parts were required to rebuild the pumps. Parts that were not readily available, including the shaft and columns, were reverse engineered and manufactured quickly to ensure a quick turnaround. An impeller with severe vane wear needed to be replaced, and OEM delivery was 8 weeks. Hydro repaired the impeller by manufacturing new vanes which were mechanically attached to the impeller.
The pumps were completed in just 4 weeks, and the rest were installed at the plant shortly thereafter. Hydro’s response to this plant’s emergency reduced costly down-time.