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Transforming Operations with Advanced Sealing Solutions
Transforming Operations with Advanced Sealing Solutions

Customer

Steel mill operating multiple sites in the Midwest.

Highlights

  • Extended Pump Lifespan: From 4 months to 1-3 years, significantly reducing the frequency of costly rebuilds.
  • Cost Savings: Approximately $850,000 annually in cleaning costs and $560,000 annually on pump rebuilds.
  • Operational Efficiency: Eliminated leakage issues, reduced frequency of maintenance, and improved overall production efficiency, leading to a cleaner and safer pump room environment.

Challenge

The steel mill was facing persistent issues with their four scupper pumps, which are vital to their production process. The use of traditional stuffing boxes with packing was causing excessive slurry leakage and rapid wear leading to repeated pump failures and significant operational inefficiencies, including:
 

  • Frequent Rebuilds: Pumps required rebuilding every four months due to severe wear on the stuffing box and sleeve, each rebuild costing $40,000.
  • High Maintenance & Cleaning Costs: The mill had to employ a sucker truck to clean up 1.5 feet of mud in the scupper pump room every other day, incurring $5,000 per day for 180 days a year.

Solution

Faced with these persistent issues and high maintenance costs, the steel mill entrusted the Reliability Solutions and Services experts at Novaspect to provide an effective mechanical sealing solution.
 
After a thorough assessment of the mill’s operational challenges, Novaspect recommended the Chesterton 170 Slurry Single Cartridge Seals due to their versatility and ability to deal with harsh and abrasive slurry environments.


 
By leveraging the expertise of Novaspect’s Reliability Solutions and Services team, the steel mill was able to successfully implement a sealing solution that transformed their operations, reduced costs, and improved overall efficiency.

Outcome

The steel mill’s adoption of the Chesterton 170 Slurry Single Cartridge Seals led to significant improvements:

  • Cleaning Cost Savings: Approximately $850,000 annual savings by reducing the need for the sucker truck service from every other day to only a few times per year.
  • Reduced Scupper Pump Rebuild Costs: With their four pumps now lasting and additional 1-3 years versus four months before needing a rebuild, the mill is saving $560,000 annually.
  • Operational Efficiency: The pumps now operate with minimal maintenance, significantly improving production efficiency and reliability.
  • Enhanced Safety and Cleanliness: The elimination of frequent leakage and the reduction in mud accumulation improved the overall safety and cleanliness of the scupper pump room.

 
The success the steel mill has realized by switching from stuffing boxes/traditional packing material to mechanical seals has prompted the site’s Maintenance Manager to recommend the Chesterton 170 Slurry Single Cartridge Seals to several additional mill sites the company operates.

Frequently Asked Questions

A good alternative or replacement for stuffing boxes and slurry pump packing is the use of mechanical seals. Mechanical seals offer several advantages over traditional packing materials, especially in harsh and abrasive environments like those found in steel mills and other heavy slurry industries. Here are some key benefits of mechanical seals:

Advantages of Mechanical Seals:
  1. Leak-Free Operation: Mechanical seals provide a more reliable seal, significantly reducing or eliminating leakage compared to packing.
  2. Extended Lifespan: They typically last longer than packing, reducing the frequency of maintenance and replacements.
  3. Reduced Maintenance: Mechanical seals require less frequent adjustments and maintenance, leading to lower operational costs and less downtime.
  4. Improved Efficiency: By maintaining a tight seal, mechanical seals help improve the overall efficiency of the pump, reducing energy consumption and wear on pump components.
  5. Enhanced Safety and Cleanliness: The elimination of leakage helps maintain a cleaner and safer working environment, reducing the risk of accidents and contamination.
 
By switching to mechanical seals, industries can achieve significant improvements in pump performance, reduce maintenance costs, and enhance overall operational efficiency.
Types of Mechanical Seals:
  • Single Cartridge Seals: These are pre-assembled units that are easy to install and provide reliable sealing for a wide range of applications.
  • Double Cartridge Seals: These offer additional sealing protection by using two sets of seal faces, ideal for handling hazardous or abrasive fluids.
  • Slurry Seals: Specifically designed to handle abrasive slurries, these seals incorporate features like non-clogging designs and robust materials to withstand harsh conditions.
 
Example: Chesterton 170 Slurry Mechanical Seal
The Chesterton 170 Slurry Mechanical Seal is an excellent example of a mechanical seal designed for heavy slurry applications. It offers:
  • Non-Clogging Design: Prevents clogging and ensures reliable operation in slurry environments.
  • High Strength: Built to handle heavy slurry and abrasive conditions with no flush.
  • Extended Service Life: Provides a longer operational lifespan compared to traditional packing.
 
Applications:
Mechanical seals are suitable for a variety of industries, including:
  • Mining and Mineral Processing
  • Steel and Metal Processing
  • Chemical and Petrochemical Industries
  • Pulp and Paper Manufacturing
  • Power Generation
  • Food and Beverage Processing
To inquire about Novaspect's engineering expertise and how you can achieve remarkable cost savings and improvements for your operation, please contact our Reliability Solutions Specialists.