Location
The Netherlands
Industry
Dredging
≥ 24 months expected lifetime
outperforms the Warman impeller’s 16 months by a wide margin
> 3 million tons of slurry handled
without a single major overhaul or loss of efficiency
CFD-engineered vanes
for perfectly balanced wear, low turbulence and sustained hydraulic efficiency
Full drop-in compatibility
with Warman G 18/16 booster pumps
81.25 % verified hydraulic efficiency
compared to 79.70 % for the reference Warman impeller at the same duty point
A major Dutch dredging company operates a booster station with two Warman G 18/16 pumps in the same pipeline. Each pump handles exactly the same slurry and process parameters.
When one impeller needed replacing, Vaikon supplied a Schegler 18×16 Gravel impeller with CFD-optimised vanes, cast in high-chrome alloy. Two months later, the second pump received a new standard Warman impeller (type GG16137HET1), made from the same high-chrome alloy. This created the perfect real-life, side-by-side test.
Challenge
The booster line continuously moves abrasive slurry with a D50 of about 539 µm, at a differential pressure of roughly 3 barg and an average throughput of 1,000–1,250 tons per hour.
Under these harsh conditions, standard impellers experienced intense abrasion and frequent replacements, which drove up maintenance costs and risked unexpected downtime.
The goal was to prove that advanced vane design can extend lifetime and improve efficiency without altering the pump casing or operating conditions.
Solution
Vaikon supplied a Schegler 18×16 Gravel impeller, fully interchangeable with the Warman G 18/16, but with CFD-engineered vanes.
Detailed CFD studies of the impeller and bowl showed lower internal turbulence and a balanced pressure field, resulting in:
- a predictable, uniform wear pattern
- higher hydraulic efficiency
- lower energy consumption
The new impeller (type 122.423.6.G.34) was validated at 2,500 m³/h and 30 m total head.
Result
- 12 months: The Schegler impeller processed 1.9 million tons—two months longer in service than the Warman impeller—and still showed less wear on eye and vanes.
- 16 months: The Warman impeller failed after 2.6 million tons.
- 18 months: The Schegler impeller had passed 2.9 million tons, remained in excellent condition, and is projected to run at least another six months, adding roughly 1 million tons.
- Throughout the run, the CFD-optimised vane design maintained superior hydraulic efficiency and reduced operating costs.
Warman impeller after 10 months of operation. Showing severe wear.
Schegler impeller after 12 months of operation. Still in good condition, with 2 extra months already in service.
Warman impeller after 16 months of operation. End of service life.
Schegler impeller after 18 months of operation. Still in good condition with at least 6 months of service life remaining.
Our parts are fully compatible with certain Warman® models. Warman is a registered trademark of Weir Minerals.
We are not affiliated with or endorsed by Weir Minerals.