Yearly Archives: 2011

New Test Cell

The major news this month is the installation and commissioning of Pump Supply & Repair Group’s  £100,000 investment in our Test Cell In short we can now Test Pumps up to 300kW and produce a full performance curve INCLUDING power, efficiency and NPSH. Our New test cell is used to quantify the hydraulic and mechanical quality of our repair and pre-test pumps to determine if work is necessary. To see our Test Facilities webpage with a video showcasing our Thermodynamic Testing Capabilities, please click here 

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Gearbox Reconditioning

The gearbox was delivered to Pump Supply & Repair Group partially seized after running with insufficient lubrication. At strip down it was also discovered that the main gear hub had fractured The remainder of the unit had all parts examined for damage and wear with images taken showing the extent of the damage. Consumable parts were itemised for replacing; these included bearings, oil seals and gaskets. Any damage to the shafts was assessed for suitability with action for correction and all critical dimensions were recorded for rebuild purposes. The main hub was replicated and the gear ring reconditioned. During assembly, all parts were set for axial and radial alignment. Full rebuild completed and the unit was returned to the customer. Another demonstration of how Pump Supply & Repair Group are able to undertake repairs and servicing to any type of rotating equipment, from parts replication through to full overhauls. Repairs Quotation Engineer Email: jmilner@pumpgroup.co.uk Direct No: 0161 864 5175

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Ash Crusher Repair

Ash Crusher Repair Pump Supply & Repair Group have recently undertaken the repair of a coal ash crusher on behalf of a UK power station. The crusher was found to be in a poor condition after many years of service. Impact damage was found to the rotor hubs which needed to be corrected by carrying weld repairs using stelite impact HS360 rod. Other areas of concern included wear to the shaft locations and wear to the gland sleeves. these areas were spiral welded and machined. Both gears were also found to be worn with excessive clearance found between the teeth. New gears were manufactured and fitted then new side sections were fabricated and fitted to badly eroded areas. Internals and externals of the hopper box were grit-blasted. The unit was then rebuilt with new copper bearing assemblies, new sets of packing rings and new gasket & shim sets. We have modified the main problem area which was the primary cause of bearing failure – gland leakage – fitted new labyrinth seals and large shaft throwers to deflect debris away from bearings. The unit was spray painted and then dispatched to the customer and is now back in operation. Repairs Quotation Engineer Email: ssmith@pumpgroup.co.uk Direct No: 0161 864 5176

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Belzona Repairs

Pump Supply & Repair Group were asked to offer advice regarding how to repair excessive corrosion to steel pipework on an exhaust steam manifold from a boiler house without replacing a complex manifold. In December 2008 the inlet flange and 1500mm of the pipe bore was coated internally in situ on site using Belzona 1511 Super High Temperature Metal to recover the surface profile, then coated with Belzona 1391 Ceramic HT Metal. Inspection twelve months later revealed that although the coating had been attacked by cavitation caused by high pressure steam, no further damage had occurred to the pipework. Once again, the Belzona coating has arrested the corrosion of the pipework, effectively increasing its life – additional coatings can now be applied to prolong the life further and avoid the expensive steel pipework replacement program previously carried out on this site. The repair was carried out during a three day shut down. Site Services Manager Email: clambley@pumpgroup.co.uk Mobile No: 07887 721900

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In House Repair Video

Pump Supply & Repair Group have recently been filming the Repair Activity in our new purpose built repair workshop. This is the first of many videos to come to showcase our experience and expertise on overhaul of all types of rotating equipment from around the UK.

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High Temp Chemical Reactor Fan

Pump Supply and Repair Group have recently refurbished a high temperature (650 °C) reactor fan for a major chemical supplier. The failure occurred on site during cold weather, where water-cooled equipment froze during January. Bearing design was from the 1960’s, so this technology was white metal liners inside cast iron water-cooled housings. The units had temperature probes to monitor bearing temperatures. As can be seen above, the water-cooled bearings have cracked in frost conditions, causing major damage resulting in plant shutdown time and loss of production. The total fan unit was disassembled, M.P.I. testing of castings was carried out. All water chambers were bead blasted to identify problems at M.P.I. test stage. Some cast iron gas welding was carried out at our Manchester workshops. The castings were cold metal stitched. All water chambers coated with Belzona 1341 Superglide. To reduce future scale up problems, the main shaft has been hard chrome coated on bearing areas to original sizes, where the white metal bearings run. Both white metal bearings were re-lined and bored, scraped to correct fit and clearance. All bearings aligned on site. The fan assembly was balanced to G. 2.5 Dynamic @ 3500 RPM. The unit was commissioned on site to aid the customer achieve tight delivery schedules. Operations Director Email: mcooper@pumpgroup.co.uk Tel: 0161 864 4678

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