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Pump Casing Castings
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(Mechanical)
(OP)
15 May 07 16:01I had posted the below in the Mechanical forum yesterday and have recieved no responses. Any help here?
I am reviewing specs for pump units for a water system. These are city water (potable water) and approx 50 mgd pumps. The casings are specified as DI or CI. Is there a quality standard for porosity and integrity of the casing? This is not a critical application so I don't think that I can probably use visual inspection methods. I am tying to define void size or porosity. Also, if the casing is cracked, I don't want this to be welded and ground unless I know the procedure and stress relief.
Also, the impellers are cast stainless steel. I have the same concerns.
Hopefully there will be no problems but I want to cover my bases if there are
(Materials)
15 May 07 17:01Rob100;
Do you know the ASTM Standard specification for the castings?
Here is what I would recommend; search on the Internet for the following information
"Steel Castings Handbook, Supplement 2" from the Steel Founders Society of America.
I believe I had downloaded my copy free. Review it for basic information regarding ASTM material specifications for castings.
The American Water Works Association (AWWA) might contain information on casting quality requirements. I did not check for this information.
If you inspect the pump castings, I would recommend a volumetric method like radiographic testing (RT). The following ASTM Standards would be applicable to you;
ASTM E94
ASTM E186 or E146 for heavier wall castings.
Regarding defect acceptance, if the AWWA does not provide guidance, you are on your own for specifying defect type and severity level for this application.
What type of cast stainless steel are the impellers?
(Materials)
15 May 07 17:49Rob, you are on the right track. Look at the ASTM specs involved and see what is there already. You will need to use sources such as the SFSA guide to set defect size limits. You should set max defect size and quantity.Visual should be fine.You might think about X-ray for flanges or other loaded parts.Requiring repair procedures is fairly typical also.
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Rust never sleeps
Neither should your protection
http://www.trent-tube.com/contact/Tech_Assist.cfm
(Petroleum)
16 May 07 01:08MSS SP-53, 54, and 55 may be of some use as will ASTM A834 as a starting point.
Steve Jones
Materials & Corrosion Engineer
http://www.pdo.co.om/pdo/
(Mechanical)
(OP)
16 May 07 10:37Thank metengr. The castings are noted as cast iron ASTM A278-Class 30; ductile iron ASTM At36 Grade 64-14-12, or ASTM A395; Cast Steel ASTM A27 Class 65-35 or A216 Grade WCB.
Stainless Steel impellers are ASTM A743 CA15.
AWWA was somewhat generic in their specification. I was hoping for something a little more difinitive. I will look at the ASTM you noted for RT.
EDStainless: xRay is a bit expensive but I may be forced into it. Thanks.
SJones: I have never used ASTM A834. I will need to get a copy of that one. Are MSS SP-53, 54, & 55 a visual inspection. I didn't think these quantfied the inspection. Thanks.
(Materials)
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16 May 07 12:06If you're looking to specify an acceptable level of porosity, aren't you pretty much forced to rely on something beyond visual inspection? I work in a steel foundry, and while I don't know a whole lot about the QC side of things I don't think we generally do much beyond a visual inspection for parts that will see relatively tame service. Of course the customer can always specify more but in most cases they don't want to pay for it.
(Materials)
16 May 07 12:23As for visual inspection, MSS SP-55 and ASTM A802 are the standards we typically use.
(Materials)
17 May 07 09:50I used to work in casting some large bolted-bowl pumps. If we were doing large units we would x-ray the flanges. For smaller units we didn't bother, visual only.
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Rust never sleeps
Neither should your protection
http://www.trent-tube.com/contact/Tech_Assist.cfm
(Materials)
17 May 07 09:52I do not have much to add at this late stage. Pump casings in grey iron or DI are usually sound and pressure tightness is not a major issue. The neck region might need to be checked for any sweating. It is not advisable to carry out any weld repairs on the castings as the alloys are amenable to crack. Any defect will get revealed during machining. Radiography is expensive and not commonly adopted.A good foundry should be capable of giving you a good quality castings.In the case of stainless steel impellers most of them are simple ,radiography can be done of necessary , and they can be easily repair welded. Importance should be given to flow path in the impeller.Try to use impellers made using ceramic cores. These will give a clean internal surface with no gas defects or sand inclusions.I am providing a few references . Also if you can visit the links for grey iron and ductile irons a wealth of information is available.E1030-05 Standard Test Method for Radiographic Examination of Metallic CastingsE802 Reference Radiographs for Gray Iron Castings Up to 4 in. [114 mm] in ThicknessE689 Reference Radiographs for Ductile Iron CastingsA743/A743M-06 Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General ApplicationASTM A536-84(1999)e1Standard Specification for Ductile Iron Castings
" All that is necessary for triumph of evil is that good men do nothing".
Edmund Burke
(Mechanical)
(OP)
17 May 07 10:11Thanks. Since I started this, I have inspected 3-18" diameter castings for the bowls on vertical turbine pumps and have found pin holes and cracks. My experience shows pin holes can grow to large air pockets once machining starts. The cracks are poor foundry practices or other damage. My challange now is to review repair procedures or demand that these are re-cast. I'm obviously not a metalurgist. It appears my suspicions were correct. Thanks again for you help and references.
(Materials)
17 May 07 10:24It is rather surprising that you have encountered these defects. Perhaps pinholes were found in DI castings. This can be due to poor Mg treatment. Cracks might be from air setting sands or high levels of S and P in the metal.It is best advised not to review these for salvaging,but reject them right away.
" All that is necessary for triumph of evil is that good men do nothing".
Edmund Burke
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One important factor that is frequently disregarded in the effective functioning of industrial pumps is the caliber of the pump casting components. These components are the foundation of a pump's operation. Therefore, choosing the appropriate ones is crucial to maximizing performance and lifetime.
Pump systems' dependability and performance are critical in the fields of fluid dynamics and mechanics. A pump's efficiency has the power to make or break an activity, whether it is employed in construction, industrial processes, or any number of other uses. It is where the knowledge of a trustworthy pump casting parts manufacturer becomes useful since they offer the essential elements that define how successful a pump is. The trait is not only a desirable trait in the complex world of pump systems; it is a process to success.
Choosing the best manufacturer for pump casting parts is both a science and an art. It's a process that requires dexterity, expertise, and a steadfast dedication to quality. Impellers, casings, and housings are examples of pump casting parts that are essential to a pump's operation. The lifetime, effectiveness, and efficiency of a pump can be greatly impacted by the materials used, the manufacturing techniques used, and the subtleties of the design.
This post will discuss the significance of selecting a trustworthy supplier of pump casting parts and will also highlight important considerations to make.
Industrial pumps are constructed using pump casting pieces. The performance of the pump is greatly influenced by parts like diffusers, volutes, casings, and impellers. The effectiveness, robustness, and dependability of the overall pump system are directly impacted by the caliber of these components. Therefore, to guarantee trouble-free operation and lower maintenance costs, it is essential to choose the appropriate pump casting parts.
Finding trustworthy pump casting parts suppliers is the first and most crucial step in getting premium parts for your pumps. Why it matters is as follows:
Reputable manufacturers implement strict quality control procedures. They produce long-lasting, industry-standard pump casting parts by utilizing cutting-edge materials and production methods. Selecting a reputable manufacturer guarantees that the parts you obtain will be of a constant caliber.
Skilled producers possess a profound comprehension of the design and operation of pumps. Considering variables like flow rates, pressures, and material compatibility, they may offer insightful advice on how to choose the best casting parts for your particular pump application.
Reputable producers frequently provide customizing choices. It enables you to customize pump casting parts to meet your unique needs and ensure optimal performance and a precise fit. Customization may be essential to getting the intended outcomes.
Many considerations need to be made when selecting a manufacturer of pump casting parts, including:
Casting pieces made of different materials are needed for different pump applications. A reliable supplier ought to provide a variety of materials, such as cast iron, bronze, stainless steel, and others, to satisfy the needs of different industries. Make sure the manufacturer can provide the best material for your particular requirements.
It is essential to comprehend the production procedure that the company employs. Superior accuracy and consistency are provided by contemporary casting techniques, including investment casting and precision casting. Verify if the producer produces high-quality parts using cutting-edge techniques.
Inquire about the quality control methods used by the company. Reputable businesses put their products through extensive testing to make sure they either meet or surpass industry requirements. A dedication to quality can be demonstrated by certifications such as ISO 9001.
Think about requesting parts that are customized to your needs from the manufacturer. Optimizing casting parts to your unique needs can improve pump performance and system efficiency as a whole.
Timely delivery and effective supply chain management are crucial. Select a manufacturer who has demonstrated the ability to fulfill deadlines. Ask about after-sale support as well since this kind of help might be crucial for pump system maintenance.
However, price matters, and quality should always be the first priority. Compare the prices of casting components made by various manufacturers, but always place quality first. Long-term financial savings can be achieved by purchasing high-quality parts since they require less upkeep and replacement.
Also Read: Explore Casting Processes for Production of Automobile Parts
To demonstrate the significance of selecting an appropriate manufacturer, let's examine a real-life case study.
A new pump casting part was needed for a chemical processing plant because of its extremely corrosive application. They chose a reputable company renowned for its proficiency in corrosion resistance and material selection after doing a thorough investigation. A specially coated, made-to-order stainless steel casting part was advised by the manufacturer to survive the harsh chemicals.
The end product was a pump that greatly decreased maintenance costs and downtime while simultaneously outperforming the plant's performance requirements. In the end, the initial cost of a premium, personalized casting component proved to be beneficial.
When it comes to industrial pumps, quality counts, choosing the appropriate pump casting parts from a reliable supplier is essential. Superior casting components guarantee the effectiveness, longevity, and dependability of pump systems, resulting in reduced expenses and enhanced overall functionality.
Think about things like material selection, production procedures, quality assurance, customizing possibilities, lead times, and cost when selecting a manufacturer of pump casting components. These factors should be carefully considered, and by dealing with a knowledgeable, trustworthy manufacturer, you may get the best casting components for your particular application and enjoy trouble-free pump operation for years to come. Remember, the upfront investment in quality pays dividends in long-term efficiency and cost savings.
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