Fundamentals REV 5 PDF

1
An easy-to-understand introduction to
slurry pumps and systems
This is the shell or

volute of a very, very,
very, very large slurry
pump.
These are people.
Readers Guide
For Our Customers
Editor & Designer Mary A. Sicard

Project Editor Thomas Mueller
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).
Production Controller Pam Welty

Tech Team Bob Courtwright,
Tom Wujcik, Richard Inglett,
Reab Berry and Kevin Kuehne
Copyright 2005
GIW Industries Inc.
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.
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 expert 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
[email protected]
Slurry Pump Fundamentals
Contents
Chapter 1: What Is Slurry? .......................................................... 9
Slurry Pumps vs. Water Pumps ....................................................................... 9
Flow Limitations ....................................................................................... 10
Solids Limitations ...................................................................................... 11
Selection of Wear Materials ......................................................................... 23

HARD METAL CONSTRUCTION ............................................................................................. 24
WHITE IRONS ................................................................................................................. 24
STEELS ......................................................................................................................
Elastomer Construction .............................................................................. 25

Ceramic Wear Parts ................................................................................... 25
Corrosion Resistance and Wear Resistance ....................................................... 25
Wear Resistance Range ............................................................................... 26
pH Ranges ............................................................................................... 26
Chapter 5: Hydraulics .............................................................. 29

Pumps and Curves ..................................................................................... 29
Chapter 2: Slurry Pumps Defined ............................................... 13

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

CLASSIFICATIONS AND EXAMPLES ......................................................................................... 16
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 ............................................................................................. 20
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
PERFORMANCE CURVE ...................................................................................................... 29

SYSTEM CURVE ............................................................................................................... 31
THE INTERSECTION .......................................................................................................... 32
Head ...................................................................................................... 32
NET POSITIVE SUCTION HEAD (NPSH) .................................................................................... 32
Vapor Pressure and Cavitation ...................................................................... 33

CAVITATION ................................................................................................................... 33
NPSHR .......................................................................................................................... 33
NPSHA .......................................................................................................................... 34
CAUSES OF CAVITATION ..................................................................................................... 34
HOW TO FIND THE CAUSE .................................................................................................. 34
Pumping Froth.......................................................................................... 35
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
FRICTION LOSSES IN NON-SETTLING SLURRIES ......................................................................... 41
Viscosity ................................................................................................. 41
NEWTONIAN AND NON-NEWTONIAN LIQUIDS ........................................................................... 41
OTHER NON-NEWTONIAN FLUIDS ......................................................................................... 43
Sump Arrangements ................................................................................... 43

Multiple Pump Installations .......................................................................... 44
PUMPS IN A SERIES ........................................................................................................... 44
PUMPS IN PARALLEL ......................................................................................................... 44
Slysel ..................................................................................................... 44
Chapter 7: Best Efficiency Point ................................................. 45

Chapter 4: Wear Protection ...................................................... 23
Wear ...................................................................................................... 23
Corbrasion ............................................................................................. 23
Optimal Efficiency ..................................................................................... 45

Radial Load .............................................................................................. 45
Axial Load ............................................................................................... 46
Shaft Deflection ........................................................................................ 47

Water Hammer ......................................................................................... 47
Chapter 8: Technical Descriptions .............................................. 51

Metal Pumps ............................................................................................ 51
LCC HARD METAL SERIES (LCC-M) ......................................................................................... 51
FEATURES ............................................................................................................... 52
APPLICATION ........................................................................................................... 52
SIZE RANGE ............................................................................................................. 52
LSA-S SERIES .................................................................................................................. 52
FEATURES ............................................................................................................... 52
APPLICATION ........................................................................................................... 53
SIZE RANGE ............................................................................................................. 53
Duties Related to Slurry Type ....................................................................... 63

FRAGILE SLURRIES ........................................................................................................... 63
HYDROCARBON SLURRIES (OIL AND REAGENTS CONTAMINATED) ................................................... 64
HIGH TEMPERATURES ABOVE 212F (100C) SLURRIES .............................................................. 64
HAZARDOUS SLURRIES ...................................................................................................... 64
CORROSIVE SLURRIES (LOW PH) .......................................................................................... 64
HIGH VISCOSITY FLUIDS (NEWTONIAN) .................................................................................. 64
HIGH VISCOSITY FLUIDS (NON-NEWTONIAN) ............................................................................ 64
Selection by Industrial Application ................................................................. 65

HARD ROCK MINING ......................................................................................................... 65
OIL SANDS ..................................................................................................................... 66
PHOSPHATE ................................................................................................................... 66
FGD ............................................................................................................................. 66
INDUSTRIAL PROCESS ....................................................................................................... 66
Rubber Pumps .......................................................................................... 53

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

VERTICAL ...................................................................................................................... 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
Chapter 10: Computerized Pump Selection ................................... 67

Slysel ..................................................................................................... 67
SOFTWARE AND HARDWARE REQUIREMENTS ........................................................................... 68
ORDER INFORMATION ....................................................................................................... 68
Chapter 11: General Maintenance .............................................. 69

Maintenance ............................................................................................ 69
RECOMMENDED MAINTENANCE SCHEDULE .............................................................................. 69
DAILY ........................................................................................................................... 70
WEEKLY ........................................................................................................................ 70
QUARTERLY ................................................................................................................... 70
SEMI-ANNUALLY .............................................................................................................. 70
Impeller Removal ...................................................................................... 71

IMPELLER BALANCING ....................................................................................................... 71
Fastener Torque ........................................................................................ 72

TORQUE ACCURACY ......................................................................................................... 72
TORQUE CHARTS ....................................................................................................... 72
Mechanical Seals ....................................................................................... 72

Bearing Temperatures ................................................................................ 73
LUBRICATION OIL OR GREASE? .......................................................................................... 74
CAUSES OF BEARING FAILURES ............................................................................................ 75
Chapter 9: Application Guide .................................................... 61
Vents and Breathers ................................................................................... 76
Selection by Duty ...................................................................................... 61

COARSE PARTICLES .......................................................................................................... 61
FINE PARTICLES .............................................................................................................. 61
SHARP (ABRASIVE) PARTICLES ............................................................................................. 62
HIGH PERCENT SOLIDS ...................................................................................................... 62
LOW PERCENT SOLIDS ...................................................................................................... 62
FIBROUS PARTICLES ......................................................................................................... 62
Duties Related to Head and Volume ............................................................... 62

HIGH HEAD .................................................................................................................... 62
VARYING HEAD AT CONSTANT FLOW ..................................................................................... 62
VARYING FLOW AT CONSTANT HEAD ..................................................................................... 62
HIGH SUCTION LIFT .......................................................................................................... 63
HIGH FLOW ................................................................................................................... 63
LOW FLOW .................................................................................................................... 63
FLUCTUATING FLOW ........................................................................................................ 63
Chapter 12: Total Cost of Ownership ........................................... 79

Importance of making Smart Pump Purchases ................................................... 79
How GIW Can Help ..................................................................................... 80
Predicting Wear ........................................................................................ 80
Calculating Energy Costs ............................................................................. 81
Chapter 13: Troubleshooting ..................................................... 83

Why Isnt My Pump Pumping? ....................................................................... 83
Warnings ................................................................................................. 83
Chapter 1: What Is Slurry?
Chapter 1:
EXCESSIVE PUMP DISCHARGE PRESSURE .......................................................................... 83
EXCESSIVE LEAKAGE AT SHAFT SEAL .............................................................................. 83
PUMP DELIVERS INSUFFICIENT FLOW RATE ....................................................................... 83
INCREASE IN BEARING TEMPERATURE .............................................................................. 84
BEARING CONTAMINATION ........................................................................................... 84
HIGH TEMPERATURE OR LEAKAGE AT THE STUFFING BOX ..................................................... 84
OVERHEATING OF PUMP CASING .................................................................................... 85
PUMP CASING LEAKS .................................................................................................. 85
PUMP FLANGE LEAKS ................................................................................................. 85
MOTOR OVERLOAD .................................................................................................... 85
VIBRATIONS OR ABNORMAL NOISES ................................................................................ 86
Help Is Here ............................................................................................. 86
Chapter 14: Appendix ............................................................. 89

Temperature Conversion Chart ..................................................................... 89
Mass Conversion Chart ................................................................................ 89
Velocity Conversion Chart ........................................................................... 89
Flow Conversion Chart ............................................................................... 90
Volume Conversion Chart ............................................................................ 90
Length and Distance Conversion Chart ............................................................ 91
Chapter 15: Glossary ............................................................... 93

Chapter 16: References ........................................................... 99
Chapter 17: Where It All Comes Together ................................... 101
Capabilities ........................................................................................... 101
TESTING AND DEVELOPMENT ............................................................................................
DESIGN ENGINEERING .....................................................................................................
MANUFACTURING ..........................................................................................................
PRODUCTS ...................................................................................................................
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101
102
102
History ................................................................................................. 103

Ownership ............................................................................................. 103
How To Contact GIW ................................................................................. 103
GIW INDUSTRIES ............................................................................................................
SERVICE CENTERS ..........................................................................................................
GIW REGEN SERVICE CENTER ......................................................................................
ARROYO PROCESS EQUIPMENT INC. ..............................................................................
FT. MCMURRAY SERVICE CENTER .................................................................................
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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 may be 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 about six
miles.
See Chapter 1.1 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 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 usually run slower than water pumps to help reduce
parts wear.
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 Chapter 2.2 Basic Relations for Flow of Simple Fluids in Slurry
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 in.
(300 mm). However,
sphere passage in
large dredge pumps
can be up to 18 in.
(450 mm).
The solids transported in this dredging operation were

as large as a hard hat.
See Chapter 2.4 Basic Relations for Slurry Flow in Slurry Transport Using
Centrifugal Pumps.
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Chapter 2: Slurry Pumps Defined
Chapter 2:
Slurry Pumps Defined

A slurry pump is a type of centrifugal pump designed for transporting solids.
It isnt designed for pumping clear liquids. The less liquid thats used in
slurry pumping, the better. It doesnt make sense to add additional fluids that
will need to be removed later in the process.
A centrifugal pump uses centrifugal force to impart velocity (speed) to a fluid
or slurry. Centrifugal force pushes something outward when its spinning
rapidly around a center. Consider a swing ride at the fair. As
the rotational speed increases,
the people in seats slide away
from the center pole toward the
swingss outer edge.
Another example? Centrifugal
force causes water to be thrown
from an automobile tire while its
rotating.
A centrifugal pump acts on the
same principle, except the tire
becomes an impeller and the
vanes help move the water.
However, the pump impeller
doesnt do all the work. Its only
part of the pump design. The
medium being pumped must be
controlled.
Centrifugal force pushes something

outward when its spinning rapidly around a
center.
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The volute (pump shell) helps control

the flow and transforms the velocity of
the liquid into static pressure and
controls the product being pumped.
Chapter 2: Slurry Pumps Defined
Chapter 3: Slurry Pump Design &

Components covers the parts of a
slurry pump in greater detail.
See Chapter 8: Centrifugal Pumps

in Slurry Transport Using
Centrifugal Pumps.
DRY
Most horizontal slurry pumps are installed
dry, where the drive and bearings are kept
out of the slurry and the wet end is closed.
The pumps are free standing and clear from
any surrounding liquid.
Volute (Shell)
Vanes
Impeller
The volute or pump shell helps

control the flow.
Markets & Applications for Slurry Pumps

Market
Application
Mill Discharge
SAG Mill, Rod Mill, Ball Mill
Cyclone Feed
Primary, Secondary, Finishing Scalping
Dewatering Feed
Screen , Fine Screen, Magnetic Separator, Hydro

Separator, Vibrating Screen or Shaker, Filter
Feed
Tailings Pump
First Stage Pump, Booster Pump, Tailings Feed

Pump, Flume Pump
Thickener
Underflow, Overflow, Thickener Feed
Dirty Water
Process, Process Return, Booster Transfer Pump
Dredge
Hydrotransport, Jetting, Booster Pump, Ladder

Pump, Cyclone Feed, Wash Water Handling
Installations
There are three types of installations: dry, semi dry and wet.
SEMI DRY
A special arrangement can be used for
dredging applications, where horizontal
pumps are used with the pump wet end and
bearings flooded and a dry drive. This
requires special sealing arrangements for
the pump bearings.
Wet End
Part of the pump that gets
wet from the pumping fluid.
It includes the:
Shell
Impeller
Hub/Suction Liner
Shaft Sleeve/
Stuffing Box
The sump pump has a flooded wet end

installed at the end of a cantilever shaft (no
submerged bearings) and a dry drive.
WET
A fully submersible pump and drive are necessary for certain slurry pump
applications.
Wear Conditions
The following slurry classifications are used in pump design selection to
ensure good wear performance under a variety of working conditions and
applications.
These classifications are based on GIWs proprietary selection program Slysel.
This program is discussed in detail in Chapter 10: Computerized Pump
Selection.
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Chapter 3: Designs & Components
Chapter 3:
CLASSIFICATIONS AND EXAMPLES
Classification
Example
Class 1: Mildly Abrasive
Thickener Overflow
Class 2: Slightly Abrasive
Screen Feed
Class 3: Significantly More Abrasive
Sand Plant Operation
Class 4: Highly Abrasive
Mill Discharge, Tar Sand

Hydrotransport and Tailings
Slurry Pump Design &

Components
Basic Designs
The three basic slurry pump designs are horizontal, vertical and submersible.
Horizontal
Vertical
Basic Components
The basic components of a slurry pump are the:
Impeller
Shell
Drive
Suction plate/liner
Sealing arrangement
Bearing assembly
Submersible
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The impeller, shell and suction liner are the key wet end wear components on
all slurry pumps. The pump performance is determined by the design of
these three parts. All other mechanical parts serve to seal, support and protect
them.
Vane Designs
The impeller vanes are the guts of the impeller. Vane
design is critical to wear and hydraulic performance of
the pump.
Bearing Assembly
Shell
The shell derives its name from a spiral-shaped volute
casing surrounding the pump impeller. One function
of the shell is to pick up the flow coming from around
the impeller, convert it into a desirable flow pattern
and direct it to the pump discharge.
Impeller
Another function is to reduce the flow velocity and

convert its kinetic energy to pressure energy.
The mathematical
logarithm found in a
seashell is used in all
pump design.
Shell
Suction Plate/Liner
Impeller
The impeller attaches to the pump shaft and imparts energy
to the fluid being pumped. There are three types of
impellers: closed, open and semi open.
CLOSED IMPELLERS
Closed impellers are preferred in slurry pump applications
where high efficiencies are required.
Closed Impeller
SHELL TYPES
Volute, semi circular and
circular are shell types or
casings. No matter which
type shell is selected,
theres a trade off between wear and efficiency.
The more volute the shell, the
greater the efficiency and the wear.
The more circular the shell, the less
the wear and the efficiency.
Solid Shell
Split Shell
A volute casing is like a seashell. Its a curved funnel. It reduces the speed of
the liquid and increases the pressure. This is the most popular design today.
OPEN IMPELLERS
Open impellers are slightly less efficient but are more effective for applications with a slurry thats a mixture of a fluid,
solid and gas such as froth pumping.
In the circular casing design, the impeller has a constant clearance between its
outside diameter and casing.
Open Impeller
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Split and Solid Shells
The shell of most hard metal pumps is one solid piece. A one-piece shell
simplifies routine maintenance and is cost effective because of simpler sealing
requirements.
The shell must be split for rubber-lined pumps so that the lining and parts
can be replaced as needed.
Shaft and Bearings

SHAFT
The shaft transmits torque from the drive to the impellers.
BEARINGS
Rolling element bearings are used to support the shaft and absorb axial
thrust. Lubrication can be oil or grease. Oil lubrication allows for higher speeds.
Suction Liner
Drives for Slurry Pumps
The suction liner is the part that has the highest wear, especially in the nose/face area.
There are three basic drive designs for slurry

pumps: belt, gearbox and direct.
Suction Liner
Shaft Seals
There are three shaft seal designs: stuffing box, mechanical seal and expeller.
The basic function of a shaft seal is to separate rotating and non-rotating
parts.
STUFFING BOX
This standard seal design uses
a lantern ring and packing.
MECHANICAL SEAL
A mechanical seal is used when
gland water isnt available or cant
be added to the process or when external
leakage and process dilution are undesirable.
BELT DRIVES
Belt drives are used for both horizontal and vertical pumps, and include the motor, vbelt and
sheaves. Belt drives allow for cost-effective speed
changes by varying the diameter of the sheaves.
V-Belt Side-Mounted Drive
Expeller
Mechanical
Seal
Stuffing Box
EXPELLER
The expeller is a secondary impeller positioned behind the main impeller. An
expeller is used in applications where mechanical seals dont work. Expellers
are a more cost-effective option than mechanical seals.
GEARBOX DRIVES
Gearbox drives are used for horizontal pumps.
They are typically used on larger motors and
pumps. A gear reducer can change the output
speed from the motor to the pump. Its most
often used for 300 hp and larger motors.
DIRECT DRIVES
Direct drives are used for both horizontal and
vertical pumps. This drive directly connects the
motor to the pump shaft. Direct drives are the
optimal selection when speed change isnt necessary.
V-Belt Overhead Drive
Gearbox Drive
Direct Drive
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Chapter 4: Wear Protection
Chapter 4:
Wear Protection
Wear
Wear life is the most critical factor in the design of a slurry pump. Wear resistance is a key consideration for both hydraulic design and material selection.
See Chapter 10.2: Wear-Resistant Materials in Slurry Transport Using

Centrifugal Pumps.
Corbrasion
Corbrasion is GIWs trademarked term for the combination of abrasion and
corrosion that creates unique wear conditions in slurry pumps.
Abrasion is wear produced by hard particles that are moving and forced
against a solid surface. The particles producing the abrasion are harder than
the surface they are hitting. The particles usually have sharp, angular edges.
Corrosion is the loss of material caused by the interaction between the pump
material and chemical products within the slurry.
Selection of Wear Materials

The proper material selection helps combat the effects of Corbrasion. Material
selection is based on:
Solid size
Slurry temperature
Impeller speed
Solid shape
Slurry pH
Solid hardness
Slurry chemical content
23
HARD METAL CONSTRUCTION

Hard irons and steels, such as white cast irons and martensitic steels, are used
most often in the construction of slurry pumps. White cast irons offer considerably higher wear resistance than steel.
steels would be destroyed by corrosive action. They are recommended for

high boiling point liquids at elevated temperatures.
White Irons
Elastomers are available as urethane or natural rubber liners and impellers.

Elastomer linings are usually specified when:
White iron is a cast iron that is free of graphite. Most of its carbon content is
present in the form of hard carbides. GIWs Gasite white irons are:
Grade
Gasite
Description
NiHard IV
4G, 6G
ASTM A532, Class I, Type D
Cr-Mo
18G, 20G
ASTM A532, Class II
High-Cr
27G, 28G
ASTM A532, Class III
Special
29G
Ultra-high strength/toughness
Special
T32G, 38G
Eutectic/hypereutectic grade
Special
OS34G
High wear with improved corrosion

resistance (for some applications such as
Oil Sands)
Special
30G
Regular corrosive-erosion grade
Special
40 G
Premium corrosive-erosion grade
Special
T90G
Super corrosive-erosion grade
Elastomer Construction
The solids are fine.

The particles do not have sharp edges.
The presence of tramp material is minimal.
Oils, solvents or hydrocarbons arent present.
The pH is less than 6.0.
The head is below 131 feet (40 m).
The temperature is below 150 F (65 C).
Ceramic Wear Parts

Ceramic wear parts are used for highly abrasive slurries where parts are
experiencing extreme wear. They are not suitable for high-impact and highpressure applications.
Corrosion Resistance and Wear Resistance

T32G
White iron is usually preferred when:
The solids are greater than .25 inches (6 mm).

The pH is greater than 4.5.
Temperatures are to 250 F (120 C).
The slurries are hydrocarbon based.
The particles are coarse or sharp.
Tramp material or debris may be present.
18G
38G
OS34G
28G
Wear Resistance
24
4G/6G
29G
40G
T90G
High-Alloy Martensitic Steels
CD4MCU
81D
Steels
GIWs steels are martensitic and heat-resistant grades (18CS, HH and HK).
Steels are distinguished by their ability to serve where carbon and low-alloy
80D/35C
Ni-Resist 82D/83D
65D
SS316
Corrosion Resistance
This chart
shows the
relative corrosion and wear
resistance of
various alloys,
which may
vary because of
the application
and other
factors.
25
Wear Resistance Range

This chart shows the regular and possible wear resistance range for various
alloys.
Regular Wear Resistance Range
Possible Wear Resistance Range
82D/83D
65D
CD4MCu
Marten. Steel
Alloys
26
40G
29G
6G
OS34G
18G
T32G
0
20
40
60
80
100
120
140
160
Wear Resistance Index
pH Ranges
This chart shows the relative pH range for various alloys.
4G
18G
T32G
28G
OS34G
40G
T90G
pH
10 11 12 13 14 15
180
200
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Chapter 5: Hydraulics
Chapter 5:
Hydraulics
Pumps and Curves

Pump efficiency is determined principally by two parameters (head and flow)
in addition to other factors such as properties of the fluid, impeller design
and motor speed.
An improperly applied pump with a high efficiency can be worn to total
failure within just a few hours. A thorough knowledge of the duty is necessary to reduce wear on the pump. In fact, most pump problems arise because
the pumps performance characteristics dont match the application requirements. This results in higher power consumption, and shorter bearing and
wear life. The system parameters and pump performance must be matched
carefully to ensure efficient, trouble-free operation.
The easiest way to visualize this requirement is to consider two separate
curves: a pump performance curve and a system curve.
A pump performance curve is a graphical representation of the head (hydraulic pressure) produced by the pump for various flow rates at a given speed.
The curve is always downward sloping, which means head decreases as flow
rate increases.
A system curve is a graphical representation of the head required for a given
system at various flow rates. In slurries, the system curve is more complex
and often resembles a U formation.
PERFORMANCE CURVE
A complete performance curve array includes:
A number of operating speeds with a constant impeller diameter
29
280
60%
70%
1100 rpm
Pump performance prediction is difficult. GIW has developed sophisticated

computer models through years of experience and can predict performance
before the pump is ever built. However, pump curves can be certified only by
full-size performance testing in accordance with the Hydraulic Institute
Standards in an approved laboratory.
75%
80%
82%
240
83%
83%
1000 rpm
82%
80%
78%
200
900 rpm
30
0
160
75%
hp
25
See Chapter 8: Centrifugal Pumps in Slurry Transport Using Centrifugal
0
hp
800 rpm
20
hp
Pumps.
16
120
hp
700 rpm
13
hp
50
500 rpm
25
40
400 rpm
0
1000
hp
rpm
000
R at 1
NPSH
hp
500
NPSHR at
rpm
2000
3000
4000
5000
6000
7000
SYSTEM CURVE
System curves represent graphically the energy (head) required to move
slurry through a piping system (including process equipment) at various flow
rates.
Gallons Per Minute
The curve data is based on

A pump performance curve is a graphical
representation of the head produced by the
clear water, so curves must be
pump at various flow rates.
adjusted when pumping slurries. Your GIW representative
or Slysel, GIWs proprietary selection program, can assist you with these
calculations and modifications.
Required energy is plotted on

the vertical axis and given in
terms of head. Capacity is
plotted on the horizontal axis
and is given in cubic meters
per hour or gallons per minute.
At a given speed, slurry pumps can be operated at a variety of flow rates.

However, only one specific flow rate achieves the maximum efficiency. This is
called the Best Efficiency Point (BEP).
System curves for liquids are

always upward sloping,
whereas slurry system curves
may be U shaped and difficult to predict. In most cases,
slurry system curves can be
determined only experimentally in a laboratory environment. Your GIW representative
can assist you in getting an
accurate system performance
curve test in the GIW Hydraulic Laboratory.
The power to operate a pump can be calculated from the information presented on the performance curve using one of the following formulas:
Metric
P = H x Q x SG
367 x Eff
H = Head in Meters
Q = Capacity in Cubic Meters per Hour
Eff = Efficiency in Percent
SG = Specific Gravity of the Slurry
P= Power in Kilowatts
U.S.
BHP = H x Q x SG
3960 x Eff
BHP = Brake Horsepower
H = Head in Feet
Q = Capacity in Gallons per Minute
Eff = Efficiency in Percent
SG = Specific Gravity of the Slurry
280
240
Total Dynamic Head
hp
hp
75
600 rpm
80
10
Data about the head

produced by the pump
over a range of capacities
Power required to
deliver a given flow and
head
Efficiency ratio of energy transferred to
energy required (power)
for various flow rates
Net Positive Suction
Head (NPSH) required.
(See NPSH section in
this chapter.)
Total Dynamic Head
30
200
160
120
80
40
0
0
1000
2000
3000
4000
5000
6000
7000
Gallons Per Minute
A system curve is a graphical representation

of the head required for a given system at
various flow rates.
31
280
60%
70%
1100 rpm
75%
80%
82%
240
83%
83%
1000 rpm
Vapor Pressure and Cavitation
82%
80%
78%
200
900 rpm
30
0
160
75%
hp
0
25
hp
800 rpm
If vapor pressure is reached, vapor bubbles form and follow the liquid into
the impeller to areas with higher pressure. The vapor bubble then collapses or
implodes in these areas. This creates extremely loud noises. These small
implosions are called cavitation.
20
hp
16
120
hp
700 rpm
0
hp
40
400 rpm
50
25
hp
hp
hp
75
600 rpm
10
80
500 rpm
Head
If the suction pressure is too low, the pressure in the suction area decreases to
the lowest possible pressure (the vapor pressure) of the pumped liquid.
13
THE INTERSECTION
Pumps always operate at the
point where the system curve
intersects the pump performance curve. This point is
called the duty point. It represents the capacity where the
energy required to move the
liquid through the piping
system equals the energy
transferred to the liquid by the
pump.
Total Dynamic Head
32
hp
R
NPSH
m
00 rp
at 10
500 rpm
NPSHR at
0
7000
0
1000
2000
3000
4000
5000
6000
The Total Dynamic Head
Gallons Per Minute
(TDH) is the sum of kinetic and
potential energy per unit of
Pumps always operate at the point where the
fluid transferred from the
system curve intersects the pump curve.
impeller vanes to the fluid. In
pumping terminology, head is often used when referring to TDH. Head is
usually expressed in meters or feet.
NET POSITIVE SUCTION HEAD (NPSH)

Net Positive Suction Head (NPSH) is an important concept for judging the
suction behavior of a centrifugal pump.
A drop in the static pressure, particularly in the suction (inlet) area, occurs as
the material flows across the pump impeller. The magnitude of this pressure
decrease depends upon the: rotational speed, operating point, design of the
impeller inlet, velocity and static pressure of the approaching flow and its
density, and viscosity.
The static pressure of the liquid must be above the vapor pressure inside the
pump to avoid cavitation. This is achieved by having sufficient pressure on
the suction side of the pump and a well-designed pump inlet.
CAVITATION
Cavitation is more than air bubbles in the liquid.
In most cases, cavitation is the liquid boiling at
ambient temperatures because of the reduction
in pressure. Cavitation should be suspected
when:
Dont
operate a pump if
cavitation is suspected.
The problem must be
corrected!
Pump capacity is reduced.

The head produced by the pump is
reduced.
Noise can be heard when the pump is
running.
Pitting or other damage can be seen on the pump impeller and shell.
Cavitation can be an issue when the operations are at a high altitude or when
pumping liquids at a high temperature. These variables may not have been
considered during pump selection.
NPSHR
All pumps require a value for NPSH. This value is called Net Positive Suction
Head Required (NPSHR). NPSHR is not a calculated value. It is a property of
the pump. All pump curves show the NPSHR for assorted flows and speeds.
However, the criteria for NPSHR must be defined for your application.
The criteria can be based on a head requirement for a given flow rate and
speed. As NPSH is reduced, head remains constant for a time and then begins
to drop off.
33
34
For slurry pumping systems, a head reduction up to five percent is usually

acceptable. Therefore, the pump can be operated safely within these parameters, which must be predetermined.
A similar process holds true for efficiency, but isnt used as regularly as head.
As NPSH is reduced, efficiency remains stable until the pressure reduction
causes efficiency to drop. Too low of an NPSH can cause cavitation.
NPSHA
The complete pump system must provide the Net Positive Suction Head
Available (NPSHA) to function properly without cavitation. NPSHA is a
system characteristic and must be calculated. The value of NPSHA must
always be greater than the NPSHR. The safety margin against cavitation is
defined as NPSHA minus NPSHR.
To calculate NPSHA, add all the pressure heads and then subtract all losses in
the piping system on the suction side.
NPSHA = Atmospheric pressure (converted to head) +
static head + pressure head the products vapor pressure
the friction loses in the suction piping, valves and fittings
See Chapter 8.3: Cavitation and Net Positive Suction Head or page 191, Net
Positive Suction Head in Slurry Transport Using Centrifugal Pumps.
Pumping Froth
The transfer of froths with a slurry pump is a special-purpose application.
The large proportion of air in froth adversely affects the pump performance.
The usual relationships for predicting the pump performance dont hold true.
The selection process also requires special considerations.
Follow these steps when selecting a froth pump:
1. Oversize the pump. Oversizing the pump helps in handling froth by
increasing the pumps impeller eye diameter. This allows the pump to
run at a lower speed.
2. Avoid pump throttling. The suction or inlet pipe must be at least the
same size as the outlet pipe
3. Increase the sump height.
Proper discharge orientation can assist in evacuating air from the pump.
CAUSES OF CAVITATION
What causes cavitation?
The flow rate is too high for the given suction and speed.
Atmospheric pressure is too low.
The application is at a high altitude.
The pump speed is too high for given suction and flow.
HOW TO FIND THE CAUSE

To find the cause of cavitation:
Use gauges.
Check pump speed.
Check pump suction (inlet) for blockage.
Refer to the pump performance curve.
35
36
Chapter 6: Slurry Pump Systems
Chapter 6:
Slurry Pump Systems
Overview
Once the operating conditions have been selected, pump selection amounts to
determining the specific performance of each available pump for the head
and flow required and selecting the best pump suited for the duty.
Pumps must be selected by matching their head/flow performance to the
requirements of the piping systems as explained in Chapter 5.
The largest energy savings are made through the design and control of the
pump system. Unfortunately, pumps are too frequently oversized because of
uncertainty over future plant expansion and system characteristics.
Never overestimate the system resistance. Doing so results in a greater flow
and a higher power consumption. You also risk overloading the motor and
experiencing cavitation, high wear or gland problems. Always use the best
estimate of system head. Add safety margins to the calculated power only.
Pipe Systems
The pump provides flow and develops hydraulic pressure (head) to overcome the differential in head between two points in pumping systems. This
total head differential consists of pressure head, static head, velocity head and
total friction head produced by friction between the slurry and the pipe,
bends and fittings.
Use head instead of pressure to measure a centrifugal pumps energy because
the pressure from a pump changes if the specific gravity (weight) of the liquid
changes, but the head wont.
37
38
Head is measured in feet or meters and can be converted to common units for
pressure as psi or bar.
The head of a pump in metric units can be expressed as:

h = (p2 - p1) / ( g) + v22 / (2 g)
Types of Pump Head

Total Dynamic Head
Total head when the pump is running.
Total Static Head
Total head when the pump isn't running.
Static Suction Head

Static Suction Lift
Head on the suction side with pump off if the head is

higher than the pump impeller.
Head on the suction side with pump off if the head is
lower than the pump impeller.
Static Discharge Head
Head on discharge side of pump with the pump off.
Dynamic Suction Head/Lift
Head on suction side of pump with pump on.
Dynamic Discharge Head
Head on discharge side of pump with pump on.
Pumps will pump all fluids to the same height if the shaft is turning at the
same rpm. The only difference between the fluids is the amount of power it
takes to get the shaft to the proper rpm. The higher the specific gravity of the
fluid, the more power is required.
The total friction head is the most difficult to determine because of the complex, nonlinear nature of the friction loss curve. This curve can be affected by
many factors.
A pumps vertical discharge pressure head is the vertical lift in height. Its
usually measured in feet or meters of water at which a pump can no longer
exert enough pressure to move water.
If the discharge of a centrifugal pump is pointed straight up into the air, the
fluid pumps to a certain height or head. This is called the shut off head. In the
flow curve chart for a pump, the shut-off head is the point on the graph
where the flow rate is zero.
This maximum head is mainly determined by the outside diameter of the
pumps impeller and the speed of the rotating shaft. The head changes as the
capacity of the pump is altered.
h = total head developed (m)(metric units)

p2 = pressure at outlet (N/m2)
p1 = pressure at inlet (N/m2)
p = density (kg/m3)
g = acceleration of gravity (9,81) m/s2)
v2 = velocity at outlet (m/s)
Pump flange conditions are unknown, so select one point on each side of the
pump where you know the conditions and then allow for pipe work losses
between these points and the flanges to determine the total head at the
flanges.
Friction Losses
The resistance to flow as a liquid moves
through a pipe results in a loss of head and is
called friction.
STRAIGHT PIPES
The friction loss in a straight pipe varies with:
Pipe diameter
Pipe length
Material (roughness)
Flow rate (velocity)
Never oversize
your pump by adding a
safety factor to the
head. Oversizing
can result in unnecessary
capital expense and
untold start-up costs.
Instead, apply the factor
to the power required by
the pump.
To determine friction loss:

Look it up in a table.
Extract it from a Moody diagram.
Calculate from a semi-empirical formula such as the William and
Hazen Formula.
Use Slysel, GIWs pump selection program. (See the end of this chapter
for more information.)
39
40
FITTINGS
When a system includes valves and fittings, an allowance for additional
friction is necessary, because the fittings can add a significant amount to the
total dynamic head that must be produced by the pump.
FRICTION LOSSES IN NON-SETTLING SLURRIES

We highly recommend that you calculate the friction loss of non-settling
slurries with the aid of computer software such as Slysel. Manual assessments
can be difficult with all the associated variables.
Total Equivalent Length (TEL) is the most common method for calculating an
allowance for additional friction. It can be used for liquids other than water.
The fitting is treated as a length of straight pipe giving equivalent resistance
to flow.
It is very important that all of the losses in a slurry system be calculated in the
best way possible. This provides the correct head and capacity. It also enables
the pump to balance the total system resistance and to operate at the correct
duty point.
TEL = Straight pipe length + equivalent length of all pipe fittings

SLURRY EFFECTS ON FRICTION LOSSES
Friction losses are also impacted by slurries because they behave differently
than clear water. Slurries must be classified as either settling or non-settling
(viscous). As a rule of thumb, slurries with particle size < 50 micron are
treated as non-settling.
FRICTION LOSSES IN SETTLING SLURRIES
The calculation of friction losses for settling slurries is very involved and best
accomplished using computer software such as Slysel. For short runs of pipe
at higher velocities, head loss can be taken as equal to the water loss.
When calculating the pipe friction losses for slurry, allow for a certain increase when compared with the losses for clear water. Assume the suspension
will behave like water for concentrations of around 15 percent by volume.
At low velocities, head loss is difficult to predict and there is a real risk of
solids settling out and blocking the pipe. The minimum velocity nomogram
provides a safe minimum velocity. (A nomogram is a chart representing
numerical relationships.)
See Chapter 5: Heterogeneous Slurry Flow in Horizontal Pipes in Slurry

Viscosity
Pull the trigger on a water pistol and the water squirts out. Pull the trigger
harder and the water squirts out faster. Fluids resist flow. This phenomenon is
known as viscosity. Viscosity is a measure of the thickness of the liquid. Think
of it as a slurrys ability to flow.
Molasses and motor oil are thick or high viscosity liquids. Gasoline and water
are thin or low viscosity liquids. Viscosity discussions generally includes two
types of liquid: Newtonian and non-Newtonian.
NEWTONIAN AND NON-NEWTONIAN LIQUIDS
Newton devised a simple model for
fluid flow to demonstrate how hard
you have to pull the trigger to how fast
the liquid will squirt out of the pistol.
Frederick A. Senese, an associate
professor in the Department of Chemistry at Frostburg State University in
Maryland, explains it this way on General
Chemistry Online:
Picture a flowing liquid as a series of layers of liquid sliding past each other. The resistance to flow arises because of
the friction between these layers. If you want one layer to
slide over another twice as fast as before, youll have to overcome a resisting force thats twice as great, Newton said. The
slower one layer slides over another, the less resistance there is, so if
41
42
there wasnt a difference between the speeds the layers were moving, there would be no resistance. Fluids, like water and gasoline,
behave according to Newtons model and are called Newtonian
fluids.
But ketchup, blood, yogurt, gravy, pie fillings, mud and cornstarch
paste dont follow the model. Theyre non-Newtonian fluids, because doubling the speed that the layers slide past each other
doesnt double the resisting force. It may less than
double (like ketchup) or it
may more than double (as
in the case of gravy).
Thats why gravy thickens as its stirred and why
struggling in quicksand
makes it harder to escape.
For some fluids such as
mud or snow, you can
push and get no flow at
alluntil you push hard
enough and the substance
begins to flow like a
normal liquid. This is
what causes mud slides
and avalanches.
Two or more pumps can be operated in a
Most high-concentration, fine
series when required head cant be reached
particle slurries are nonwith a single pump.
Newtonian and have plastic
behavior. Plastic means that
energy must be put into the slurry to start it to flow.
To establish friction losses or effects on pump performance for plastic slurries,

the true plastic dynamic viscosity and the energy level (yield stress) for the
float point must be verified. GIW can provide test work to verify these parameters.
OTHER NON-NEWTONIAN FLUIDS

There are other fluids in which the shear stress is not linear with shear rate.
Dilatant fluids, such as paper pulp, increase in viscosity with energy input.
Pseudo-plastic fluids, such as mayonnaise or paint, decrease in viscosity with
energy input.
Sump Arrangements
Poor sump design is often the largest contributing factor to inadequate pump
performance. Most pump malfunctioning can be attributed to the suction side
of any pump installation. For best results include the following in the design:
Sump feed should be below the liquid surface to avoid air entrainment. This is especially important with frothy slurries.
Sump connection to the slurry pump should be as short as possible. A
basic rule is five times the pump diameter in length and the same size
as the pump inlet.
Suction pipe should never be smaller than the suction flange of the
pumps and should be one size larger to accommodate settling velocity.
Drain connection should be included on the inlet pipe. Use a floor
channel under the drain to recover the slurry.
A reinforced,
flexible inlet
connection is
recommended for a
possible
vacuum
condition.
Include a full
bore shut off
valve.
Two or more pumps can be operated in parallel when
required flow cant be achieved with a single pump.
43
44
Chapter 7: Best Efficiency Point
Chapter 7:
Separate sumps are preferred for standby pump installations. This
avoids settling in the standby pump sump when not in use.
Best Efficiency Point
Multiple Pump Installations

Two reasons for using multiple installations of slurry pumps are:
1. When the head is too high for a single pump.
2. When the flow is too great for a single pump.
Optimal Efficiency
PUMPS IN A SERIES
When required head cant be reached with a single pump, two or more
pumps can be operated in a series. This application is used often to meet the
high head required in long-distance tailings or to reduce the head of a singlestage pump in a demanding mill circuit application. Series operation allows a
lower operating speed, which results in reduced wear.
The efficiency of the pump and its components is one of the factors that
affects a pumping systems performance, and optimizing a pumping systems
efficiency can result in up to a 60 percent reduction in energy and maintenance costs. But, in the real world, pumps are seldom operated at their Best
Efficiency Point (BEP).
The discharge from the first-stage pump is connected directly to the second
pump. This doubles the head produced. Two identical pumps in a series
provide the same system efficiency as the individual pumps.
BEP, in technical terms, is the point where the brake horsepower going into
the pump is the closest to the water horsepower coming out of the pump. Its
at this point where the pump has the least amount of shaft vibration and
deflection.
PUMPS IN PARALLEL
When required flow cant be achieved with a single pump, two or more
pumps can be operated in parallel. The discharge from both pumps is connected to the same line. Parallel pumps must be identical. Parallel pumping
for slurry is uncommon.
Slysel
Slysel, GIWs proprietary pump selection program, is easy to use and aids in
all aspects of pump selection. Its free for GIW customers. Slysel:
Calculates performance curves.

Evaluates slurry and horizontal friction.
Calculates overall pipeline system resistance.
Selects or evaluates pumps.
Evaluate operational factors.
Pump efficiency can decrease significantly when the pump operates away
from the its BEP. Over-specifying the duty when selecting a pump increases
energy costs.
In this chapter, we look at reasons pumps dont operate at BEP.
See Chapter 13, Practical Experience with Slurry Systems in Slurry

Radial Load
The radial direction is 90 degrees or at a right angles to the centerline of the
shaft.
45
46
The radial bearing supports the shaft from defection caused by impeller or
drive loads. There are multiple causes of a radial deflection of the shaft,
including:
A non-concentric shaft sleeve

Pipe loads at the pump flange, either physical or thermal
Operating off the BEP causes the shaft to deflect in a radial direction.
Dynamic unbalance of the rotating assembly changes as the impeller
wears.
The pump and driver are misaligned. The coupling may not compensate for this.
Vibration causes radial deflection. Vibration includes cavitation and
water hammer.
See Chapter 5 for information on cavitation. Water hammer is discussed at the
end of this chapter.
Axial Load
Axial movement is movement along the length of the shaft. The thrust bearing resists movement axially and transfers this force from the shaft to the
housing.
The pressures generated inside a centrifugal pump work on both the stationary and rotating components.
On single-inlet impellers, an axial force exists because of differences in pressure on the front and back of the impeller and the difference in the areas
subject to the pressure. Axial thrust is the sum of these unbalanced forces
acting in an axial direction.
Several ways to compensate for axial thrust are:
Install a double-row thrust bearing in the end of the casing next to the
coupling.
Install a wear ring on the back of the impeller with holes drilled
through the impeller to equalize some of the forces.
Use pump out vanes or radial ribs on the back of the impeller to reduce
the pressure behind the impeller.
Use a hydraulic balancing device mounted in a chamber connected to
the suction side of the pump or a low point in the system as some
multi-stage pumps do.
Shaft Deflection
A number of forces act on the shaft to cause it to deflect including:
Forces causing rotation (torque) of the shaft

The weight of the parts
Radial and axial hydraulic forces
Vibration
The deflection can be along the length of the shaft (axial) or 90 degrees to the
length of the shaft (radial).
Here are suggestions to help reduce the deflection caused by operating off the
BEP:
Go to a larger diameter shaft replacing the mechanical end with a
larger unit.
A variable speed motor makes sense if the pumps primary head is
friction head.
Tell the operator to operate the pump at its BEP. (Good luck with that
one!)
Water Hammer
Water hammer is a destructive pressure surge that takes place in piping
systems when the rate of flow changes suddenly. This is of greater significance in low head pumping systems than in high head systems.
There are multiple causes for this change in rate of flow including:
47
48
The power to the pump is lost for some reason and the pump slows
down faster than the fluid flowing in the lines and liquid separation
takes place.
Small pipe sizes can cause rapid velocity changes.
A valve closes rapidly in the suction line.
Surge tanks and air chambers can protect some piping systems from
the affects of water hammer.
See Chapter 13, Section 13.6 Water Hammer in Slurry Transport Using
Centrifugal Pumps.
49
50
Chapter 8: Technical Descriptions
Chapter 8:
Technical Descriptions
A number of factors affect GIWs slurry pump design including:

Certified performance by hydraulic testing in GIWs Hydraulic Testing
Laboratory, the largest lab of its kind in the world
Computer-generated, cutting-edge hydraulic designs for high efficiency and maximum wear life
Innovative wear materials, such as GIW Gasite white iron, for longer
parts wear life
Linatex rubber liners, a superior wear product compared to any other
natural rubber in todays market
Special design features, such as a split stuffing box, to reduce maintenance down time
Designs with optional mechanical seal or expeller
Metal Pumps
LCC HARD METAL SERIES (LCC-M)
The LCC hard metal slurry pump is
a horizontal, end suction, centrifugal
slurry pump.
The hydraulic wet end consists of
three components: a shell or casing,
an impeller and a suction plate/liner
to permit easy removal for maintenance and inspections.
The LCC-M slurry pump does not
require a separate outer housing.
LCC Hard Metal Series pumps are

suitable for high discharge head, mildly
corrosive slurries and a wide range of
particle sizes.
51
52
Features
A horizontal shaft
A single-wall shell
A three-vane impeller and a suction plate/liner of high-chrome white
iron for long, predictable wear life
The standard fused carbide-coated shaft sleeve provides a smooth,

extremely hard surface for long packing life. Optional sleeve materials
are available.
Application
The pumps are suitable for high discharge head, mildly corrosive slurries and
a wide range of particle sizes. Custom materials are available for highly
corrosive slurries.
LSA-S slurry pumps are widely used in ore transport, mill discharge, cyclone
feed, tailings and plant process. The LSA can also be found in environmental
cleanup, dewatering (low head type), pulp and paper (liquor transfer), food
processing (sugar and sugar beets), coke and resin pumping and ash handling.
Size Range
Size Range
Application
Discharge diameters: 2 - 12 in. (50 - 300 mm)

Flows to 17,000 gpm (3865 m3/h)
Total head to 300 ft. (90 m)
Capabilities to 700 hp (520 kW)
Shaft sizes from 1.5 - 5 in. (35 - 125 mm)
LSA-S SERIES
Pumps in the highly efficient LSAS Series are primarily for heavyduty service in a wide variety of
slurry applications. The pumps
rugged design and wet end parts
are made from proprietary GIW
Gasite material, which is recognized worldwide for superior
abrasion resistance and excellent
performance. Optional impeller
designs can fine tune pump performance to meet your specific system needs.

Flows: 100 - 60,000 gpm (22 - 13600 m3/h) (Contact GIW for higher
flow needs.)
Total head to 300 ft./stage (91 m)
Capabilities to 2,500 hp (1862kW)
Special high-pressure design up to 900 psi (62 bar) test available
Rubber Pumps
LCC RUBBER-LINED SERIES (LCC-R)
The LCC pump design incorporates state-of-the-art hydraulic design and
wear materials for heavy-duty applications. LCC pumps provide a low
total cost of ownership.
LSA-S slurry pumps are widely used in ore

transport, mill discharge, cyclone feed,
tailings and plant process.
Features
The heavy-duty, split-cartridge bearing assembly with spherical roller

radial bearings and steep angle, self-aligning thrust bearing ensures
maximum efficiency and minimum shaft deflection.
The series offer two pedestal sizes,

which cover the entire range of seven
wet end sizes to maximize system
flexibility and reduce inventory.
Interchangeable rubber and metal
designs enable you to make the best
material choice for any application.
Easy wet end change can adapt
existing pumps to new applications.
LCCs are available with either oil or
grease lubrication.
LCC-R slurry pumps are suitable for

moderate discharge head, fine
particles and highly corrosive
slurries.
53
54
Features
The LCC Rubber-Lined Series features a split casing design with

molded, replaceable rubber liners.
The LCC rubber pump is fitted with a Linatex rubber liner. Linatex is
a superior wear product compared to any other natural rubber in
todays market.
Liners may be specified in a variety of natural and synthetic rubbers to
meet specific slurry applications
The liners are vulcanized to metal backing plates and captured at the
split casing, suction discharge flanges and stuffing box area to maintain hydraulic and hydrostatic integrity.
Application
LCC-R slurry pumps are suitable for moderate discharge head, fine particles
and highly corrosive slurries.
LSR pumps are lined with Linatex rubber, a superior wear product
compared to any other natural rubber in todays market.
The LSR holds its original operating efficiency rating longer than any
of its competitors.
Application
Designed for heavy-duty mill circuit and fine grind slurries.

Size Range

Flows to 40,000 gpm (9000 m3/h)
Shaft sizes: 5 - 6 in. (125 - 175 mm)
Vertical Pumps
Size Range

Flows to 17,000 gpm (3865 m3/h)
Capabilities to 700 hp (520 kW)
Shaft sizes: 1.5 - 5 in. (35 - 125 mm)
LSR
With the addition of the LSR, GIW now
offers a solution for all of your slurry
pumping needs. The LSR is built to
operate at the lowest total cost of
ownership with its superior hydraulic design.
Features
Wear components are available in a wide

range of proprietary hard iron alloys
along with rubber and urethane casing
The LCV Series is ideal for
liners to meet any application.
industrial process pumping,
tailings disposal in mining
The v-belt drive system accepts high
and pit use for dredge and
horsepower motors and the structural
other operations.
parts can be ordered in corrosion resistant alloys.
Performance and efficiency, plus easy maintenance, provide the best
value with a GIW vertical slurry pump.
Features
Double-wall construction
with an outer ductile iron
casing and inner molded
rubber liners
Three-vane impellers cast of
hard metal or polyurethane
VERTICAL
GIW heavy-duty vertical pumps are the answer
for the most aggressive corrosive and abrasive
slurry applications. These rugged pumps combine long wear life with high sustainable hydraulic efficiency for the lowest total cost of
ownership.
The LSR is designed for heavy-duty mill

circuit and fine grind slurries.
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Applications
The LCV Series is ideal for industrial process pumping, tailings disposal in
mining and pit use for dredge and other operations.
Size Range
Discharge sizes: 2 - 12 in. (50 - 300 mm)

Flows to 6000 gpm (1360 m3/h)
Total head up to 125 ft. (38 m)
Shaft sizes: 3.5 - 8 in. (90 - 200 mm)
Cantilevers: 35 - 71 in. (900 - 1800 mm)

Capabilities up to 4,000 hp (2980 kW)
Hydrostatic tested up to 600 psi
TBC
These pumps are constructed as horizontal, end suction centrifugal pumps to
give maximum resistance to wear while simplifying maintenance. The conventional single-wall design transfers stress loads to non-wearing side plates
in high-pressure applications.
Features
High-Pressure, Multi-Stage Slurry pumps

WBC
The patented design of the WBC slurry pump incorporates state-of-the art
hydraulic wear technologies for severe-duty, high-pressure applications. The
pump shell is designed to reduce bending movements and associated stresses
that can cause a structural failure during a pressure surge.
Features
The shell, impeller and suction liner are made of GIW Gasite
alloys, which are recognized for superior abrasion resistance.
Three-vane impellers offer maximum particle size passage.
The pump is equipped with GIWs proven heavy-duty mechanical
end with spherical roller radial bearings and separate steep-angle
thrust bearing.
The standard fused carbide-coated shaft provides a smooth, extremely hard surface for long packing life. Optional sleeve materials are available.
Applications
Primary services are in ore and tailings transport lines subject to sudden
pressure spikes.
Size Range
Discharge diameter: 18 - 26 in. (460 - 660 mm)

Impeller diameters: 46 - 54 in. (1168 - 1372 mm)
Flows to 60,000 gpm (13600 m3/h )
Impeller and casing hydraulics are designed with proprietary GIW

computer programs for high efficiency, maximum suction performance and large solids passage.
Standard bearing assemblies feature an integrated Bearing Isolator
System. Designed by GIW, it consists of a labyrinth seal machined into
the end cover and covered with an elastomer v-ring and metal flinger.
This double seal excludes contaminants.
Forward flush stuffing box comes standard on TBCs.
Oil lubrication is
standard. GIWs
Blue 150 synthetic
oil is included for
the initial fill.
Optional oil recirculation and powered
coolers are available
options for large
units.
Applications
TBC pumps feature high

head and high flow rates
for dredging, pipeline
booster stations and other
severe duties.
TBC pumps feature high head and high flow rates
for dredging, pipeline booster stations and other
severe duties.
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Size Range

Flows: 5,000 - 140,000 gpm (1136 - 31900 m3/h)
Total head to 300 ft.+/stage (91 m)
Capabilities beyond 12,000 hp (8940 kW)
Visit www.giwindustries.com or call your local GIW representative.
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Chapter 9: Application Guides
Chapter 9:
Application Guide
Selection by Duty
Slurry pumps are often selected based on the duty or the type of slurry being
pumped. A thorough knowledge of the application is needed to select the
right pump for the application and to reduce wear on the pump.
When selecting by duty, consider the:
Size, shape and density of the solids being pumped
Head requirements
Type of liquid
Use the following guidelines when selecting your pump by duty:
COARSE PARTICLES
Any solid larger than 12 in. (300 mm)
Metal pumps (Never use rubber.)
Upper limit solid size is 2 in. (50 mm).
The impact on the impeller is the limitation.
Recommendation: LSA, WBC, TBC
FINE PARTICLES
Use rubber for sharp particles.
If particles are not sharp, rubber or metal is fine.
Recommendation: All series
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SHARP (ABRASIVE) PARTICLES

Use rubber for sizes below .20 in. (5 mm).
Use metal for sizes above .20 in. (5 mm).
HIGH PERCENT SOLIDS

Solids percentage must be below 50 percent by volume.
LOW PERCENT SOLIDS

Light-duty pump, high-efficient pump
Recommendation: LCC, LCV
FIBROUS PARTICLES
Problem with particle and air blocking
Recommendation: LCC or LSA with open shroud impeller
HIGH SUCTION LIFT

Metal pumps are preferred, because of the risk of a rubber lining
collapse on high suction lifts.
Maximum practical suction lift 10 - 12 ft. (3 3.5 m), depending on
specific gravity
Priming device required.
Pump and inlet pipe must be filled with liquid before starting up the
pump.
HIGH FLOW
Use parallel pumps installations. (See Chapter 6, Slurry Pump Systems.)
Increased cavitation risk
LOW FLOW
Use metal to avoid overheating rubber linings.
Recommendation: LHD
Duties Related to Head and Volume

HIGH
HEAD
High speed/high wear
Maximum head on metal pump 410 ft. (125 m)
Maximum head on rubber impeller 148 ft. (45 m)
VARYING HEAD AT CONSTANT FLOW

Use a multi-speed drive or variable drive.
VARYING FLOW AT CONSTANT HEAD

Use variable drives.
FLUCTUATING FLOW
Use horizontal pumps with variable speed drive or fixed speed vertical
pumps.
Duties Related to Slurry Type

FRAGILE SLURRIES
Both metal and rubber pumps can be used.
Both horizontal and vertical pumps can be used.
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HYDROCARBON SLURRIES (OIL AND REAGENTS CONTAMINATED)

Cannot use natural rubber.
Use synthetic seals.
Use metal pumps.
Selection by Industrial Application

This general guide is provided for reference only. It contains some common
slurry pump industrial applications served by GIW slurry pumps.
This is a schematic of phosphate mining, a common slurry pump application.
HIGH TEMPERATURES ABOVE 212F (100C) SLURRIES

Cannot use natural rubber.
Operating limit is 275 F (135 C). Above this, bearings can overheat.
HAZARDOUS SLURRIES
Shaft sealing is critical.
Usually a closed pump system
Recommendation: Horizontal series with mechanical seals
CORROSIVE SLURRIES (LOW PH)

Use Gasite T90G.
Recommendation: LCC, LSA
HIGH VISCOSITY FLUIDS (NEWTONIAN)

Pumping is critical if the viscosity is over five times the viscosity of
water.
HIGH VISCOSITY FLUIDS (NON-NEWTONIAN)

Pump selection is difficult. Please consult your GIW representative.
HARD
ROCK MINING
Grinding circuit pumps
Floor sump pumps
Tailings pumps
Cyclone feed pumps
Tailings pumps
Thickener overflow pumps
Screen discharge pumps
Ball mill discharge pumps
LHD pump for tailings operation
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Chapter 10: Computerized Pump Selection
Chapter 10:
Computerized Pump
Selection
OIL SANDS
Hydrotransport pumps
Tailings transfer pumps
Cyclone feed pumps
Floatation froth pumps
PHOSPHATE
Matrix pit pumps
Tailings feed pumps
Clay pumps
FGD
TBC pump in oil sands
Most misapplications and problems in slurry pumping systems arise because

the key to their successful installation and operation is overlooked.
Absorber recirculation pumps

Slurry bleed pumps
Additive feed pumps
Spray recycle pumps
Prescrubber recycle pumps
Sump pumps
INDUSTRIAL PROCESS
Wash water pumps (sand & gravel)
Sand transportation pumps
Tunnel dewatering pumps
Drainage pumps
Dredge pumps
The key lies in understanding the relationship between the system and the
pump. The two must be matched carefully to ensure efficient, trouble-free
operation.
Pit pump in phosphate
Slysel, GIWs proprietary pump selection program, allows a sales representative to calculate the system and pump curves, chart their intersection and
select just the right pump for your slurry system.
Slysel
How Slysel can help:
And virtually any hydrotransport application you can think of.
The Slysel program for personal computers helps design Newtonian

liquid, settling slurry and non-settling slurry pipelines.
LSA pump in dredge
A specific pump or series of pumps can be evaluated at desired operating conditions.

The software selects the pump that delivers the maximum efficiency
for the pipeline system specified and plots the system curve and selected pump curve. Other pump and slurry characteristics are calculated and displayed.
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Chapter 11: General Maintenance
Chapter 11:
Slysel is available to GIW customers only.
Slysels pump file contains information
on over 2,500 centrifugal slurry pumps.
Branch diameters vary from 2 inches
(51 mm) to 44 inches (118 mm). The
tested water performance for the
pumps on file may be modified
automatically for slurry solids effect
using algorithms based on tests run
in the GIW Hydraulic Testing Laboratory.
General Maintenance
Maintenance
SOFTWARE AND HARDWARE
REQUIREMENTS
Windows 98, ME, NT, 2000 or XP
X86 processor or better
CD-ROM drive
ORDER INFORMATION
To order Slysel:
E-mail [email protected].
Call our Order Entry Department at 706.863.1011.
Fax requests to 706.855.5151, Attention: Order Entry Department.
A pumping systems reliability is of critical concern, but pumps are often

poorly maintained and arent given attention until they start causing problems or stop working altogether.
Maintenance practices, at their simplest level, include a periodic walk around
a site, listening to and feeling for unusual vibration from pumps to identify
which pumps are starting to wear.
At an advanced level, they include monitoring and recording
vibration using sensors and alignment with conventional techniques or laser.
An unmaintained pump can fail
catastrophically.
Whether simple or advanced, good maintenance practices reduce the deterioration in efficiency and improve the reliability of pumps. (Without maintenance, a pump can eventually lose about up to 15 percent of its original efficiency.)
RECOMMENDED MAINTENANCE SCHEDULE
Establish a maintenance schedule based on your application and internal
procedures. Use the following as a guide only:
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DAILY

Impeller Removal
Keep consistent, accurate records.
Re-adjust the impeller of a new pump after the first day of operation.
Check the oil level when the pump isnt operating.
Check the bearings for sudden temperature changes.
Check the stuffing box operation and make necessary adjustments.
Regularly monitor pressure gauges, flow indicators, recording instruments and ammeters.
Check the pump immediately if its normal running sound changes.
Check for leakage from weep holes in the pump casing that indicate
liners need to be replaced.
Gland service pressure can sometimes indicate if pipes are blocked or
if the stuffing box needs attention.
Check the v-belt drive for correct operation. New belts require retensioning after the first few days because they stretch.
WEEKLY
Re-adjust the impeller until the optimum
amount of time required is determined.
Highly abrasive applications may require
weekly adjustments while lighter duty
applications need less.
Record gauge readings.
Use proper removal techniques.

Install a break loose jig or use drop
arm.
Do not reverse the motor. This can
force impeller into the casing and
damage pump.
Use anti-seize on plug threads, but
not on hub face, when installing
Putting a new impeller on worn
the impeller.
threads results in rapid failure and
Use two release gaskets between
damage to other wet end parts.
hub and sleeve for proper sealing.
Inspect plug threads.
Make sure mating parts are suitable during rebuilds.
Never use heat to remove an impeller. Moisture
and air trapped inside can expand and explode.
GIW Impeller Lift Jigs are available from Part Sales
and are built to order for all standard and custom
pumps.
If the threads on the shaft
QUARTERLY
look like this, the shaft
Drain and refill oil.
should be scrapped.
Adjust v-belt tension and check for signs of
wear. Clean the pulley grooves and v-belts.
Clean and oil studs and threads on motor base and gland where applicable.
Repack the stuffing box and check for wear.
SEMI-ANNUALLY
Thoroughly inspect the pump.
Clean bearings and bearing housings and refill with fresh oil.
Check drains and sealing water piping and flush.
Check pump and motor alignment.
Impeller Lifting Jigs are finished in bright safety yellow paint. Theyre CAD designed according to ASME
B30.20 with welded steel plate construction. Multiple
lifting points and a threaded leveler align the impeller
for easy installation. Each lift jig is marked with the
Working Load Limit and GIW part number for fast
identification.
Impeller part numbers and pump serial numbers are
required to select the correct lift jig for each application.
Impeller Lifting Jig
IMPELLER BALANCING
All GIW impellers and expeller rotors are balanced at the factory. The standard is ISO 1940, The Balance of Rotating, Rigid Bodies. Grade G25 is used
based on the slower speed and more rugged frames of slurry pumps. The
majority of slurry service can use single plane static balance methods.
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Fastener Torque
Torque is the most important part of assembly.

As tight as the gun gets it is not the correct torque.
Use the correct bolt grade and torque chart.
Force on the wrench, thread pitch and lubrication produce clamp load
at the joint.
85 - 95 percent of the force applied is used to overcome friction.
Incorrect clamp load can cause leaks and vibration, or allow bearing
housing to move.
Never reuse fasteners in critical applications such as impeller release
rings.
Manual, air and hydraulic torque wrenches and impact guns need to
be checked and calibrated frequently.
TORQUE ACCURACY
Torque Charts
Torque charts show values for different thread diameter, pitch and lubricants.
70 percent yield value is typical.

Anti-seize requires less torque than oil.
Moly lube is not recommended.
Never use dry in assembly or value.
Use anti-seize on stainless steel fasteners or threads will be damaged.
Mechanical Seals
Mechanical seals are selected based on shaft diameter and duty conditions.
Installation and adjustment are critical.

Seal faces must be 100 percent clean.
Mechanical seals must never be run dry.
They require a minimum axial and radial shaft deflection (Limited End
Float CBA).
Refer to manufacturers instructions.
Bearing Temperatures
Depending on the application, normal operating temperatures in pumps
range from 100 - 180 F (38 - 82 C) with most running between 140 - 160 F
(60 - 71 C).
Although grease is used in
some pumps, oil is the
preferred lubricant in the
majority of pump applications. Standard bearing oils
remain effective to approximately 180 F (82 C). If
normal operating temperatures are higher, synthetic
oil should be used. If temperatures exceed 200 F (93
C), a circulating oil system
is recommended.
Higher than normal operating temperatures in pumps
can be caused by excess oil
level or too much grease.
Overheating can also be
caused by bearing or drive
misalignment, hot process
fluids and elevated ambient
temperature.
Bearings normally run
Whether simple or advanced, good maintenance
slightly hotter during the
practices reduce the deterioration in efficiency
initial break in period. This
and improve the reliability of pumps.
varies depending on pump
size and speed. Bearing
temperatures in pumps, especially those in critical applications, should be
monitored regularly.
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LUBRICATION OIL OR GREASE?

Bearing lubrication is one of the most critical aspects of pump operation, and
the type of lubricant selected impacts routine maintenance requirements.
Small pumps with light loads can be operated on grease, while heavy-duty
units require oil. The GIW LCC Series was designed to use either lubricant.
Grease fittings and a retainer ring in the housing keep the grease near the
bearing rollers. Oil-filled units have internal grooves to help circulate the oil
plus a sight gauge and temperature gauge.
The larger GIW LSA bearing assemblies are designed for use only with oil.
GIW recommends the GIW Blue Synthetic Oil for use in all pump sizes and
all manufacturers. This offers lower operating temperatures, better protection
and extended change intervals.
GIWs heavy-duty units are available with the optional recirculation kit to
lower temperature by reducing the volume of oil in contact with the bearings
while returning hot oil to the center of the housing for heat dissipation.
Oil lubrication is selected for a number of reasons:
Bearing Suppliers Most major bearing manufacturers
state that spherical roller thrust bearings should be oil
lubricated. Grease lubrication can be used in special cases,
for example, under light loads and at low speeds. The
thrust loads in slurry applications can be very significant
and cavitation must be considered. In addition, bearing
speeds are lowered when using grease.
Maintenance Oil-filled units do not require frequent
relubrication. Draining the oil at change intervals removes
contaminants and provides a visual indication of potential
wear problems.
Contamination Oil tends to wash through the bearings
and carry the contaminants into the reservoir, while grease
holds dirt close to the rolling elements.
Temperature The oil helps carry the heat from the bearing
into the casing where it can be dissipated.
Lubrication In pump applications, its difficult to keep
grease in contact with the rolling elements in adequate
quantity to replenish the oil film without a continuous
supply.
The key to long bearing life is using the correct amount of a top-grade lubricant with the right properties along with a strict maintenance schedule.
CAUSES OF BEARING FAILURES
Contamination causes most premature bearing failures. This can be the result
of excessive wear, abnormal surface stresses caused by debris or corrosion
from water or slurry contamination.
Poor lubrication practices or wrong bearing selections cause about one third
of premature bearing failures. Any bearing deprived of proper lubrication
will fail long before its normal service life. Failure can be the result of using
the wrong lubricant type, mixing lubricants, improper relubrication quantity
or maintenance, and improper additives.
Fatigue accounts for 34 percent of early bearing failures. Whenever machines
are overloaded, unbalanced or misaligned, bearings suffer the consequences.
These abnormal conditions cause unintended loads on the bearing that can
quickly add up to a dramatic reduction in service life. Premature failures from
fatigue may appear to be the result of lubrication problems.
Poor installation causes about 16 percent of all premature bearing failures.
Service personnel need to be aware of which tools to use and trained in using
them. For example, a bearing may require mechanical, hydraulic or heat
application methods for correct mounting or dismounting. Using the wrong
method can damage the bearing and shaft.
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Monitoring bearing conditions using predictive or condition monitoring

techniques can detect problems before failure occurs. A thorough analysis and
corrective action can often be applied before catastrophic failure, pump damage or production losses occur, saving the customer time and money.
Occasionally, oil leaks out of the seal. The most typical causes are worn or
missing v-rings and incorrectly adjusted flingers. An overfilled oil level or
incorrect lubricant could also allow some oil to migrate past the seal. Correcting these conditions normally eliminates the leakage.
Vents and Breathers
GIW eliminated the use of vents for the majority of pump bearing assemblies.
Unless the unit is equipped with a breather from the factory, you dont need
to install one. Breathers generally create more problems than they solve.
During operation, all powered equipment generates heat. This expands the
lubricant and air inside the housing which creates a positive internal pressure. In most industrial machinery this escapes out through a vent or breather
device to the atmosphere. As the unit cools, the oil/air volume contracts and
outside air is drawn back into the housing. This process is repeated for each
start/stop cycle. Eventually enough airborne moisture is drawn in and condensation can actually form on internal components. This can create rust on
shaft and bearing surfaces while the pump is idle.
In most slurry applications, the atmosphere surrounding the pump is generally one of high humidity and contamination generated by stuffing box flow,
plant processes and the area environment. This can migrate past the vent and
contaminate the inside of the bearing assembly. It only takes a small amount
of water to reduce dramatically the lubricating property of the oil.
By using a labyrinth seal design at each end of the shaft, GIW eliminated the
need for an external vent or breather. Lab testing indicated that the internal
pressure rise is small and is normally equalized by bleeding out past the vring seal. After the pump is stopped, the cooling cycle is very slow and results
in a slight vacuum inside the housing. This pulls the v-rings against the end
cover to further prevent contamination from spray or wash down. When the
pump resumes operation, the internal pressure simply normalizes. Where
Inpro seals are used, this internal pressure can escape between the stator and
rotor while the pump is running.
The use of synthetic oil such as GIW Blue 150 reduces the overall temperature
of the unit, thus lowering the internal pressure change. This type of oil is also
more tolerant of normal contamination and provides longer maintenance
intervals.
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Chapter 12: Total Cost of Ownership
Chapter 12:
Total Cost of Ownership
Buying a slurry pump is similar to purchasing a car: buyers who consider the
sticker price alone may be in for a shock down the road. Once your pump is
operating, several expenditures must be considered:
Power bills
Cost of replacement parts
Downtime costs
Capital expenditures
Those expenditures comprise the Total Cost of Ownership (TCO). TCO is the
total yearly cost of the pump and driver including capital, power expenses,
price of replacement parts and downtime costs evaluated over five years.
In the past, buyers didnt consider TCO when making their selections. They
considered only the lowest purchase price and perceived benefits described
by the salesperson.
We know now that the initial price of a pump is typically less than 15 percent
of the total cost of ownership, and over a 20-year period, the combined energy and maintenance costs may exceed 10 times the initial pump purchase
price.
Importance of making Smart Pump Purchases

Its important to make a smart pump purchase because:
Energy costs are rising daily.

Capital budgets are being reduced.
Profitability must be maximized.
Productivity must be increased.
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Chapter 12: Total Cost of Ownership
How GIW Can Help

GIW developed proven tools to help customers select the type, size and
operating speed that deliver the best TCO. GIW conducted TCO studies on
many pumps in different applications. These findings show that the purchase
price of a pump can be offset quickly by common operating factors:
Energy consumption
Wear life
Replacement part cost
Downtime
numerically models slurry velocities within the shell. This predicts the wear
around the hydraulic path inside the shell at the defined conditions.
This powerful program is used extensively during GIW research and design
work to test various pump shapes and determine the optimum geometry for
a particular service.
Recently, GIW expanded this program to include the impeller and suction
liner. Tools are available to model the wear of the entire wet end. These tools
allow GIW to recommend the combination of parts that provide the best
overall wear at the lowest TCO.
Predicting Wear
Calculating Energy Costs
Predicting wet end wear life expenses used to be difficult. As a general rule,
users followed the 3-2-1 rule: Three suction liners and two impellers are
normally replaced during the life of one shell. Of course, this rule varies
with operating conditions, maintenance procedures and the contents of the
actual slurry.
Most pump manufacturers can estimate energy costs. GIW takes this one step
further by actually testing pumps with different slurries in our Hydraulic Test
Lab. From these tests and computer models, customers can know how much
power will be required for a specific set of operating conditions.
Read the July 2002 article, Wear and the Total Cost of Ownership of Slurry
Pumps, by Anders Sellgren, Graeme Addie and Krishnan Pagalthivarthi.
Working with Dr.

Mihail C. Roco,
senior advisor for
Nanotechnology
National Science
Foundation, GIW
developed the
industrys first
computer program
to predict wear in
pump casings and
shells accurately.
Using operating
parameters including flow rate, concentration, size of
solids and specific
gravity, the program
GIWs Hydraulic Testing Laboratory is the largest lab of

its kind in the world.
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Chapter 13: Troubleshooting
Chapter 13:
Troubleshooting
Why Isnt My Pump Pumping?

More than 80 percent of all pumping problems are problems with the systemnot the pump.
System problems are typically related to the suction side of the installation.
Mechanical problems such as overheating of the bearings, noise or vibration
are easily detected. System problems are sometimes complex and are often
incorrectly attributed to the pump.
Warnings
Excessive Pump Discharge Pressure
Pump may be running too fast.

Excessive Leakage at Shaft Seal
Cavitation/vibration (For more

information on cavitation, see
Chapter 4: Wear Protection.)
Packing, lantern ring
Worn shaft sleeve
Pressure
Seal water
Pump Delivers Insufficient Flow Rate
Verify that the pump is correct for the head and flow system parameters. The pump curve can be used to determine the output, power and
speed.
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84
Depending on the age and service of the pump, parts could be worn
sufficiently to reduce performance.
Verify that the motor has the correct power and voltage required for
the system and is operating properly.
Verify that the pump is running at the correct speed.
Verify that the suction side has adequate Net Positive Suction Head
(NPSH) available from the system.
Check the suction pipe for air pockets, leaks, partially closed valves or
other restrictions.
Be certain that the suction inlet and impeller are not clogged.
Verify that the discharge valve is fully open.
Increase in Bearing Temperature
During the initial break in period, the bearings normally run hotter.
Excess temperature may be attributed to hot process fluid.
Verify correct oil level. Overfilling causes viscous drag, which builds
heat.
Verify oil viscosity. High viscosity and mineral oils cause drag and
build heat, especially at higher speeds.
Misalignment of the motor or coupling can create excess bearing load
and increased heat.
Insufficient coupling clearance between the pump shaft and motor
shaft can add axial loads to the thrust bearings.
External pipe forces can distort the pump and bind the bearings.
Worn or damaged bearings may generate excess heat before failure.
Drag from external parts such as coupling guards can increase bearing
temperature.
Bearing Contamination
Flinger missing or incorrectly installed

V-ring seal damaged or missing
Excess leakage at stuffing box
Damaged bearing isolator
Improper maintenance
High Temperature or Leakage at the Stuffing Box
High temperature caused by packing thats adjusted too tightly.

High temperature caused by hot process fluid.
Leaking caused by excess flush pressure.
Leaking caused by a wrong adjustment.

Leaking caused by worn parts.
Excess wear of packing or sleeve:
Adjusting the packing too tightly
Insufficient flush flow or pressure
Contaminated flush water
Poor quality packing
Failure to lubricate new packing
Excess seal water pressure
Overheating of Pump Casing
Prolonged running against shut head or blocked discharge

Blocked suction? Warning! This is could create a very dangerous condition.
Insufficient NPSH available from the system
Air pockets in suction pipe or pump
Hot process fluid being pumped
Pump Casing Leaks
Casing or liner worn through

Normal or excess stuffing box flow
Defective seal between pump casing, liner or housing
Pump Flange Leaks
Defective gasket at pump flange

Incorrect flange bolt torque
Motor Overload
Verify that the motor has the correct power and voltage supply, and is
operating properly.
Verify that the motor is correct for the pump. The pump specifications
and curve can be used to determine the power and speed required.
Verify that the pumped fluid matches the system design viscosity and
specific gravity.
Coupling misaligned
Gland adjusted too tight
External pipe forces can distort the pump and bind the motor and
pump bearings.
Drag from external parts such as guards
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Vibrations or Abnormal Noises
Cavitation caused by low NPSH or blocked suction.

Impeller rubbing caused by incorrect nose adjustment.
Impeller is out of balance.
Debris jammed in impeller vanes.
Pump or motor mounting bolts are loose.
Air in system
Large solids in pumped fluid
Coupling is misaligned.
Belts are misaligned or incorrectly tightened.
Insufficient clearance between the pump shaft and motor shaft at
coupling
Worn bearings in pump or motor
Gland adjusted too tightly
Vibrations from system transmitted through piping.
Damaged or bent shaft in pump, speed reducer or motor
Help Is Here
All operators should receive proper instruction on maintaining and troubleshooting of pumps. In many modern plants, the operator and the maintenance mechanic are often the same person. If the operators know how the
pump works, they will have no trouble figuring out the solution to most
problems. All too often, the only instruction given is Keep the flow gage at a
certain point. What is actually happening with the equipment isnt understood.
GIW offers training for all skills and levels. Our REGEN service center can
service your pumps at our Grovetown, Ga., location or at your facility. We
also have service centers in Florida and Canada. Please see Chapter 17:
Where It All Comes Together for specific information.
Your local regional sales manager can arrange on-site or off-site training. Visit
www.giwindustries.com for a complete list of GIW authorized representatives.
GIW offers an annual hands-on slurry course, Transportation of Solids Using
Centrifugal Pumps, at our Grovetown facility. Visit our Web site for additional information.
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Chapter 14: Appendix
Chapter 14:
Appendix
Temperature Conversion Chart

C = (F -32)/1.8
C = K -273.15
K = C +273.15
F = (C *1.8)+32
F = R -459.67
R = F +459.67
Mass Conversion Chart

Kilogram
Grams
Pounds
Ounce
kg
lb
oz
kg
1000
2.20462
35.274
0.001
0.00220462
0.035274
lb
0.453592
453.592
16
oz
0.0283495
28.3495 0
0.0625
Velocity Conversion Chart
ft/s
m/s
Feet Per Second
Meters Per Second
ft/s
m/s
Kilometers Per Hour Miles Per Hour
kph
mph
0.304800
1.097280
0.681818
3.28084
3.60000
2.23694
0.911344
0.277778
0.621371
0.447040
1.609344
kph
mph 1.466667
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90
Chapter 14: Appendix
Flow Conversion Chart
l/s
Cubic Meters
Per Hour
Length and Distance Conversion Chart
Liters Per
Second
l/s
Cubic Feet
Per Minute
m 3/h
f3/m
Gallons (US)
Per Minute
gpm
3.60000
2.11888
15.85032
Feet
Inches
Yards
Miles
Centimeters Meters
Kilometers
ft
in
yd
mi
cm
km
ft
12
in
0.08333 1
0.333333
1.893939e-4
30.4800
0.304800 3.04800e-4
0.0277778
1.578283e-5
2.54000
0.025400 2.5400e-5
m 3/h 0.27778
f3/m 0.471947
0.58858
4.40287
yd
36
5.68182e-4
91.4400
0.914400 9.14400e-4
1.69901
7.48052
mi
5280
63360.0
1760.000
160934.4
1609.344 1.609344
gpm 0.630902
0.2271
0.1336806
cm
0.03281 0.393701
0.01093613 6.21371e-6
0.01
10e-6
3.28084 39.3701
1.093613
6.21371e-4
100
0.001
km
3280.84 39370.1
1093.613
0.621371
100000
1000
Volume Conversion Chart
l
cc
m
gal
in
ft3
Liter
Cubic
Centimeters Cubic Meters Gallons (US) Cubic Inch
cc
m3
gal
in3
ft3
1000
0.001
0.264172
61.0237
0.0353147
0.001
1e-6
2.64172e-4
0.0610237
3.53147e-5
264.172
61023.7
35.3147
3.78541
1e6
3785.41
1
0.00378541
231
0.13368
0.016387
16.38706
1.63871E-05
0.004329
5.78704e-4
28.3168
28316.8
0.0283168
7.48052
1728
1000
Cubic Feet
1 foot = 12 inches
1 inch = 2.54 centimeters
1 meter = 100 centimeters =1000 millimeters
1 centimeter = 10 millimeters
91
92
Chapter 15: Glossary
Chapter 15:
Glossary
ABRASION
Abrasion is wear produced by hard particles that are moving and forced
against a solid surface.
AVERAGE PARTICLE SIZE
The average particle size represents the behavior of a mixture of various
particle sizes in a slurry. This designation is used to calculate system requirements and pump performance.
BEP
At a given speed, slurry pumps can be operated at a variety of flow rates.
However, only one specific flow rate achieves the maximum efficiency. This is
called the Best Efficiency Point. BEP is the point where the brake horsepower
going into the pump is the closest to the water horsepower coming out of the
pump.
CAPACITY
Capacity is the gallons per minute a pump puts out.
CAVITATION
Cavitation is more than air bubbles in the liquid. In most cases, cavitation is
the liquid boiling at ambient temperatures because of the reduction in pressure.
93
94
CENTRIFUGAL PUMP
A centrifugal pump is a machine in which water or other fluid is lifted and
discharged through a pipe by the energy imparted by a wheel or blades
revolving in a fixed case. Some of the largest and most powerful pumps are
centrifugal pumps.
CENTRIPETAL FORCE
Centripetal force deflects a body from its linear path and compels it to move
along a curve.
CIRCULAR CASING
A circular casing is a type of design used with centrifugal pumps that pump a
high liquid volume rather than pumps that build a high head or pressure. In
this design, the impeller has a constant clearance between its outside diameter and the casing
CORBRASION
Corbrasion is GIWs trademarked term for the combination of abrasion and
corrosion that creates unique wear conditions in slurry pumps.
CORROSION
Corrosion is the loss of material caused by the interaction between the pump
material and chemical products within the slurry.
DUTY POINT
The duty point is where the pump performance curve crosses the system
head curve. It represents the capacity where the energy required to move the
liquid through the piping system equals the energy transferred to the liquid
by the pump.
HEAD
This is the term centrifugal pump people use in place of the word pressure. It
is also called Total Dynamic Head.
KINETIC ENERGY
Kinetic energy is the energy of a moving object.
MAXIMUM PARTICLE SIZE

This is the largest (maxiumum) particle size in a slurry under normal conditions thats expected to pass though the pump.
NEWTONIAN FLUID
Fluids, like water and gasoline, that behave according to Newtons model are
called Newtonian fluids. Newtonian fluids have a constant viscosity at a
given temperature.
NOMOGRAM
A nomogram is a chart representing numerical relationships.
NON-NEWTONIAN FLUID
Non-Newtonian fluids have a variable viscosity at a constant temperature.
The viscosity varies with the shear rate of the fluid. Multigrade motor oils,
ketchup, blood, yogurt, gravy, pie fillings, mud and cornstarch paste
are non-Newtonian fluids.
NON-SETTLING SLURRY
A non-settling slurry is a slurry in which the solids wont settle to the bottom
of the containing vessel or conduit. They instead remain in suspension without agitation for long periods of time.
NPSH
Net Positive Suction Head is the difference between the suction pressure and
the saturation pressure of the fluid being pumped.
NPSHA
The Net Positive Suction Head Available is the difference between the pressure at the suction of the pump and the saturation pressure for the liquid
being pumped.
NPSHR
The Positive Suction Head Required is the minimum net positive suction
head necessary to avoid cavitation.
95
96
PERCENT SOLIDS BY VOLUME

Percent solids by volume is the actual volume of the solid material in a given
volume of slurry divided by the given volume of slurry and multiplied by
100.
SPECIFIC GRAVITY
Specific Gravity (SG) is the ratio of the density of a substance to the density of
water. Dont confuse specific gravity with viscosity, which is a measurement
of a fluids resistance to pouring.
PERCENT SOLIDS BY WEIGHT

Percent solids by weight is the weight of dry solids in a given volume of
slurry divided by the total weight of that volume of slurry and multiplied by
100.
STATIC PRESSURE
Static pressure is usually stated in inches of water (H2O) or in millimeters of
water (mmH2O). Its essentially a measure of the differential air pressure
between the air pressures inside an application compared to the ambient air
pressure outside of an application.
PERFORMANCE CURVE
A pump performance curve is a graphical representation of the head produced by the pump for various flow rates at a given speed. The curve is
always downward sloping, which means head decreases as flow rate increases.
PRESSURE
Pressure is the force of the fluid in a hydraulic system.
SETTLING SLURRY
A settling slurry is a slurry in which the solids move to the bottom of the
containing vessel or conduit at a discernible rate, but remain in suspension if
the slurry is agitated constantly.
SHEAR RATE
Shear rate is the difference between velocity of parallel faces of a fluid element divided by the distances between the faces.
SHUT OFF HEAD
Shut off head is the maximum head that the pump can generate with a given
impeller outside diameter and horsepower driver.
SLURRY
Slurry is a mixture of something solid and a liquid.
SLYSEL
Slysel is GIWs proprietary pump selection program.
STUFFING BOX
The stuffing box is the portion of the pump that holds the packing and the
mechanical seal.
SUMP PUMP
The sump pump does just what the name implies: it pumps out a sump or pit.
SYSTEM CURVE
A system curve is a graphical representation of the head (energy) required to
move slurry through a piping system (including process equipment) at various flow rates.
TCO
Total Cost of Ownership is the total yearly cost of the pump and driver including capital, power expenses, price of replacement parts and downtime
costs evaluated over five years.
TDH
Total Dynamic Head is the sum of kinetic and potential energy per unit of
fluid transferred from the impeller vanes to the fluid. In pumping terminology, head is often used when referring to TDH. Head is usually expressed
in meters or feet.
TEL
Total Equivalent Length is the most common method for calculating an allowance for additional friction.
97
98
Chapter 16: References
Chapter 16:
VAPOR PRESSURE
The lowest possible pressure of the pumped liquid is called the vapor pressure. If the suction pressure is too low, the pressure in the suction area decreases to the vapor pressure of the pumped liquid. If vapor pressure is
reached, vapor bubbles form and follow the liquid into the impeller to areas
with higher pressure. The vapor bubble then collapses or implodes in these
areas. This creates extremely loud noises. These small implosions are called
cavitation.
VISCOSITY
Viscosity is a measure of the thickness of the liquid. Thick liquids have a high
viscosity and thin liquids have a low viscosity. Like specific gravity, viscosity
can be altered by a change in temperature, but unlike specific gravity, it can
also be altered by agitation.
VOLUTE CASING
The volute casing gets its name from a spiral-shaped casing surrounding the
pump impeller. The purpose of the volute is to convert velocity energy to
pressure energy.
WATER HAMMER
Water hammer is a destructive pressure surge that takes place in piping
systems when the rate of flow changes suddenly.
References
Dr. Mihail C. Roco
Senior Advisor for Nanotechnology
National Science Foundation
Chair, National Science, Engineering and
Technology Councils Subcommittee on Nanoscale
Science, Engineering and Technology (NSET)
99
100
Chapter 17: Where It All Comes Together
Chapter 17:
Where It All Comes

Together
Capabilities
GIWs pumps move just about any material, and they move it quickly and
efficiently. Weve learned our most valuable lessons through down-and-dirty
applications that have taken us around the globe, wherever mining, dredging
and industrial companies demand systems that expand the limits of moving
slurry.
TESTING AND DEVELOPMENT

GIWs Metallurgical Laboratory performs research and development, and
materials quality control and investigation. GIWs Hydraulic Laboratory has
performed over 350 pipeline tests using
actual slurries to predict real-world performance. Lab testing is available on a
contract basis to customers.
DESIGN ENGINEERING
GIW engineers are experts at finding
solutions. They have published more
technical papers and produced more new
designs than any other slurry pump
manufacturer. Processes include:
Advanced three-dimensional solid
CAD computer design software
GIWs engineers use advanced

three-dimensional CAD computer
design software.
101
102
Sophisticated computer programs to simulate the multiphase flow in

impeller and shell to ensure high pump performance with minimized
wear
Working closely with
academic and industrial partners the
world over to put the
most advanced
methods into practice
MANUFACTURING
GIW employees are trained
in quality control techniques and the facilities
operate under certified ISO9001 Standards. GIW uses
the latest casting technology
and equipment.
GIWs corporate headquarters is located in

Grovetown, Ga.
PRODUCTS
GIW strives to offer the lowest total cost of ownership on all projects.
Our pumps deliver excellent suction performance, high sustainable hydraulic
efficiency and long
wear life with flows
of 50 - 100,000 gpm
(11 - 23000 m3/h).
Mineral processing: coal, copper, gold, iron ore, nickel, oil sands, phosphate
Power generation: FGD systems and ash handling
Aggregate: sand and gravel
Industrial process: alumina, cement, chemical, potash, wastewater
Dredge: marine, sand and gravel
History
GIW Industries began as a small foundry and machine shop in Augusta, Ga.,
in 1891. Over the last century, GIW has made its way to the forefront of the
slurry pump industry. Today, the company is comprised of two manufacturing facilities, one in Grovetown, Ga., and the other in Thomson, Ga.
These foundries and machine shops are used for manufacturing and assembling pumps and for casting a variety of abrasion-, corrosion- and heat-resistant alloys, polyurethane and rubber
elastomers.
Ownership
As a subsidiary of KSB AG of Germany,
one of the worlds largest pump and
valve manufacturers, GIW has the
infrastructure to supply and support a
world market.
GIW and KSB together have more than
125 years of experience in pumps and
hydraulics.
Our expert service

and sales staff are
readily available to
diagnose and solve
field problems.
When youve got a complicated problem to solve, GIW/KSB is the answer.
GIW serves the

following industries:
GIWs Hydraulic Laboratory has

performed over 350 pipeline tests
using actual slurries.
How To Contact GIW

GIW has two manufacturing facilities, one in Grovetown,
Ga., and the other in Thomson, Ga.
For additional information or to find a sales representative in your area, visit

www.giwindustries.com. Call, write or fax us at:
103
104
GIW INDUSTRIES
5000 Wrightsboro Rd.
Grovetown, GA 30813
Phone: 706.863.1011
Fax: 706.863.5637
Toll-Free for Pump Emergencies: 1.888.TECH.GIW (8324.449)
SERVICE CENTERS
GIW REGEN Service Center
5000 Wrightsboro Rd.

Grovetown, GA 30813
Phone: 706.863.1011
Fax: 706.434.0770
Arroyo Process Equipment Inc.
1351 S.R. 60 West

Mulberry, FL 33860-8571
Web: www.arroyoprocess.com
Phone: 863.425.1145
Fax: 863.425.2936
Ft. McMurray Service Center
155 MacMillan Rd.

Fort McMurray, Alberta T9H 4G3 Canada
Phone: 780.713.3457
Fax: 780.713.3458
105
106
Slurry Pump Fundamentals is an easyto-understand introduction to slurry pumps and systems.

GIW engineers understand stuff like: The algebraic sum of the suction gauge head plus the velocity head at point of gauge attachment
plus the elevation head from the suction gauge centerline to the pump
datum, but, frankly, we dont. Andwere sure we dont want to.
If you feel that way, too, youll like the books straight-forward,
friendly approach. (Dont worry. Our engineers didnt write this book.
We did, however, ask them to proofread it for us.) We use simple
language to teach you about wear protection, cavitation, vane design
and viscosity. We tackle the most complex topics (efficiency, hydraulics and slurry pump systems) with all the care, kindness and clarity
and we can muster. We also:
Remind you (over and over again) that a pump always operates at the
intersection of the system curve and the pump curve.
Explain why paying attention to the design of the system in which the pump
operates can achieve significant savings.
Cover maintenance practices that reduce the deterioration in slurry pump

efficiency and improve the reliability of the system.
Include an appendix full of conversion charts and a glossary of common

terms associated with slurry pumps and pumping systems.
We doubt this will be your favorite book, but we hope youll use it to
find basic answers to questions about pumps and systems.
We worked hard to make sure our explanations are clearer
than, ummmm, slurry.
www.giwindustries.com

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What are slurry pumps used for?

What are slurry pumps used for?

What are the different types of slurry pump installations?

What are the different types of slurry pump installations?

1

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These are people.

For Our Customers

Editor & Designer Mary A. Sicard

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Slurry Pump Fundamentals

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

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

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

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

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

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

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

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

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

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

PERFORMANCE CURVE ...................................................................................................... 29

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

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

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

Chapter 7: Best Efficiency Point ................................................. 45

Optimal Efficiency ..................................................................................... 45

Slurry Pump Fundamentals

Shaft Deflection ........................................................................................ 47

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

Duties Related to Slurry Type ....................................................................... 63

Selection by Industrial Application ................................................................. 65

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

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

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

Chapter 10: Computerized Pump Selection ................................... 67

Chapter 11: General Maintenance .............................................. 69

Impeller Removal ...................................................................................... 71

Fastener Torque ........................................................................................ 72

Mechanical Seals ....................................................................................... 72

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

Vents and Breathers ................................................................................... 76

Selection by Duty ...................................................................................... 61

Duties Related to Head and Volume ............................................................... 62

Chapter 12: Total Cost of Ownership ........................................... 79

Chapter 13: Troubleshooting ..................................................... 83

Slurry Pump Fundamentals

Chapter 1: What Is Slurry?

Help Is Here ............................................................................................. 86

Chapter 14: Appendix ............................................................. 89

Chapter 15: Glossary ............................................................... 93

History ................................................................................................. 103

See Chapter 1.1 Applications of Slurry Transport in Slurry

Slurry Pumps vs. Water Pumps

Slurry Pump Fundamentals

Slurry pumps are constructed of special materials because of the abrasive

Chapter 1: What Is Slurry?