Extending Run Intervals in Oil Sands Hydrotransport
At a major oil sands operation in northern Alberta, nearly every stage of the extraction process relies on hydrotransport to move mined ore. The site processes more than 100 million metric tons of dry ore each year through four hydrotransport trains. Each train consists of four pumps in series along a 3.8-kilometer hydrotransport line, with initial particle sizes reaching approximately 110 millimeters.
Frequent Overhauls and Accelerated Wear
The customer’s existing competitor pumps were not meeting performance expectations in several of the site’s most challenging pump positions. Overhaul intervals typically ranged from 2,000 to 3,000 hours, falling short of the customer’s goal of 4,000-hour run intervals. The pumps were also experiencing high impeller vane wear, high cutwater wear, regular plugging events, and recurring issues with bearing assemblies.
The incumbent supplier made changes intended to improve run intervals, including introducing higher-cost components, but results were mixed and did not meet the customer’s expectations.
Better Performance Starts with the Right Hydraulic Fit and Smart Monitoring
Working closely with the customer, KSB GIW analyzed PI data and previous wear patterns and selected the GIW® TBC-70 L as the best hydraulic fit for the application. The initial pump configuration featured a full 28G wet end for a strong balance of wear life and cost.
The pumps were equipped with a complete GIW® SLYsight monitoring suite to track wet end wear and internal clearances in real time during operation. This data would help the customer extend run intervals by identifying when to make clearance adjustments and mapping internal wear, helping maximize the usable life of wet end components.
KSB GIW also developed a retrofit package to streamline installation of the new pumps. GIW® TBC-70 L variants were designed to mount directly to the existing subbase and wet end supports, using field measurements and laser scans to ensure an accurate fit. A third-party engineering partner designed offset spools, piping modifications, and piping support changes. KSB GIW led the removal of the existing competitor pumps and installation of the GIW® TBC-70 L pumps, supported by its Fort McMurray field service team.
This approach gave the customer a complete solution: a severe-duty slurry pump tailored to the application and supported by retrofit engineering, installation expertise, and regional service.
Significant Cost Savings Achieved with the GIW® TBC-70 L
The customer initially ordered two GIW® TBC-70 L pumps, which were installed in 2025. These pumps have achieved run intervals of up to 3,600 hours, and performance to date suggests that more than 4,000 hours may be attainable.
In addition to longer run intervals, the customer reported:
- Fewer plugging events, with those that do occur clearing more quickly
- Increased throughput
- Improved ability to recover from operational upsets, including sanding events
The GIW® TBC-70 L also provided a lower total cost of ownership, reducing parts costs by an estimated 30% compared with the competitor pumps it replaced.
Following this success, the customer ordered nine additional pumps with installations planned throughout 2026 and 2027.
