Split Volute Structure for Coated High-Chrome Submersible Pumps
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Solution Overview
Problem
Conventional heavy duty centrifugal pumps face challenges in manufacturing high chrome cast iron volutes due to poor machinability, leading to increased costs and reduced yield, while also requiring frequent maintenance and replacement of components due to wear and corrosion from harsh environments.
Innovation Solution
A split volute design made of high chrome cast iron allows for improved manufacturability and complete surface coating, reducing maintenance time and cost through a two-piece construction that facilitates easier access and application of abrasion-resistant coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high chrome cast iron is used for volute manufacturing, then abrasion resistance is improved, but manufacturability deteriorates due to poor machinability and difficulty in forming complex shapes
Solution Approach 1:
The volute is divided into two separate halves that are cast individually and then joined together. This segmentation allows each half to be more easily formed and machined compared to a single complex unitary structure, while still achieving the required abrasion resistance through high chrome cast iron material
Solution Approach 2:
Different regions of the volute can have different material properties or treatments. The interior surfaces that require machining or coating can be prepared more effectively in the segmented design, allowing local optimization of machinability and surface treatment access
2Strength
If unitary volute design is used, then structural integrity is improved, but maintenance complexity increases due to difficulty in accessing interior surfaces for coating and repair
Solution Approach 1:
By dividing the volute into two maintainable halves, the design allows interior surfaces to be accessed from the exterior through the split. This enables coating application and repair work without complete disassembly, reducing maintenance complexity while maintaining structural integrity through proper joining of the halves
3Device complexity
If one-piece volute construction is used, then manufacturing simplicity is improved, but coating completeness deteriorates due to inaccessible interior surfaces
Solution Approach 1:
The two-half construction provides access to interior surfaces that would be inaccessible in a sealed unitary design. This allows complete coating of all interior surfaces including hard-to-reach areas, while the construction remains relatively simple through the use of standard joining methods
Data Source
AI summary
A split volute for a centrifugal pump is disclosed that provides a manufacturing advantage by improving the yield of high-chrome iron casting, providing for full surface coating capability using line-of-sight spray coating systems. Performance improvements include improved pump efficiency, abrasion resistance, and volute lifetime. Additional operational cost savings are enabled through reduced time required for common volute maintenance procedures and an increased replacement interval for the volute. Taken together, these advantages reduce the total cost of ownership of the split volute pump system.