Over a period of ten years, the relationship between local pump manufacturer Sulzer Pumps SA and local supplier KEW Foundries, based in Kimberley, has been reinforced and strengthened by the increasing complexity and size of castings that have been successfully manufactured to date.

The BLEY 36/36 pump casing comprising of a top and bottom casting with a combined casting weight of 8 675 kilograms is an example of the extent to which the skills levels at KEW Foundries were challenged to meet Sulzer’s requirements.

The cap weighing 2 495 kilograms was an easy task to complete and the KEW Foundry team had no problem moulding and casting this product.

The BLEY 36/36 pump casing comprising of a top and bottom casting with a combined casting                        weight of 8 675 kilograms

The footprint of the casting measured 2 465mm length by 2 000mm width by 1280mm height

The base, which has a cast weight of 6 180 kilograms, was altogether a completely different problem with its own challenges.

Beginning with the footprint of the casting, which measured 2 465mm length by 2 000mm width by 1280mm height, the production of the mould proved to be a task that tested KEW Foundries expertise at all levels and reaffirmed the strength and value of teamwork.

Once moulded and closed, the mould measured 3 200mm length by 2 500mm width by
3 500mm height, weighed in excess of 20 000 kilograms and had to be sunk below the foundry floor by approximately 600mm to leave sufficient height for the pouring ladles to access the pouring basins at the top of the mould. One of the main cores in the mould alone weighed a staggering 3 000 kilograms.

During this time KEW was also in the process of replacing their two old 3 000 kilogram mains frequency furnaces with two new 3 000 kilogram ABP medium frequency furnaces, which were still under construction. This added more pressure in ensuring all aspects of the melting process was carefully planned and executed to provide sufficient molten metal to complete the cast in a single pour.

Approximately 7 200 kilograms of molten metal was required to fill the mould and the only furnace available for the casting was a 6 000 kilogram mains frequency Junker furnace.

The ingenuity of the KEW team was brought to the planning table with the 6 000 kilogram furnace being built up 750mm higher to melt the required volume of metal.

Once moulded and closed, the mould measured 3 200mm length by 2 500mm width by 3 500mm height, weighed in excess of 20 000 kilograms and had to be sunk below the foundry floor by approximately 600mm to leave sufficient height for the pouring ladles to access the pouring basins at the top of the mould. One of the main cores in the mould alone weighed a staggering 3 000 kilograms

The furnace used for the casting was a 6 000 kilogram mains frequency Junker furnace

Before dispatch to Sulzer, the fettled casting was dimensionally inspected and dye-penetrant tested by the KEW QC department to ensure that the casting was sound and would pass the final pressure testing requirements after machining.

In the end the combined team effort of the foundry and engineering team resulted in a casting that met all Sulzer’s expectations.

For further details contact KEW Foundries on TEL: 053 841 0474 or visit www.kewfoundries.co.za