The 60" Foster Wheeler (60 VAK 4.8R.S.E) Circ Water Pump at a Mid Western Power Generating Facility had been vibrating excessively, however the plant had hoped it could make it through the summer without having to take the pump out of service during peak power generating period. On June 22 the pump vibration levels increased requiring the plant to take offline one of two large vertical Circ Water pumps at the worst possible time of the year.
Three (3)-week turnaround was required on this 60" (1.5 meter) Foster Wheeler Circ Water Vertical. Right is the old bronze impeller. Left is the new 316SS impeller.
ProCast was advised the customer needed a replacement impeller in three weeks. As you can see from the above picture, the old bronze impeller is severely worn. ProCast received the old impeller at our Foundry/Pattern Shop in Cullman, Alabama on June 30. Working through the 4th of July weekend, the impeller was reverse engineered and the pattern was completed, thanks to our skilled and dedicated team at this location. Immediately after pattern completion, the impeller was poured in 316 SS. The impeller was then shipped to our production machine shop in Zachary, Louisiana where it was machined, balanced, and shipped within the 3 week required time.
Impeller being keyed during the machining phase.
The customer successfully started the pump up on August 1st. Flow, pressure, and amp draw were measured to be exactly per the hydraulic curve provided by the OEM. The customer was very pleased with the quick turnaround and the pump's performance.
ProCast stands ready to provide this Quick React capability to your customers in power generation and other industries.
Repaired pump returning to power plant for installation.