Yearly Archives: 2012

Rheinhütte Pumps Solve Customer’s Corrosion Problems

The customer had several pumps at a water treatment plant that kept failing within a very short period of time after installation. The product being pumped was a highly aggressive concentrated chemical used in the water treatment process. The corrosive nature of the chemical meant that the product was attacking the pumps internals, damaging the impeller and volute and causing the seals to fail prematurely, which lead to dangerous chemical leaks. Pump Supply & Repair Group quoted to repair the damaged pump, and also quoted to supply better quality chemical process pumps as an alternative. After analysing the situation, our engineers advised to fit a Friatec Rheinhütte RCN Ku PE1000 pumps, as given the operating conditions they would far outlast the repaired pumps, giving longer mean time between failure and better value for money. Friatec Rheinhütte, who Pump Supply & Repair Group represents exclusively in the UK, are specialist Chemical Pump Manufacturers, offering several ranges of Engineered Chemical Process Pumps. The pumps selected are made from an ultra-high molecular polyethylene, with an operating temperature range from -50 to 80oC, and which has resistance to corrosion which exceeds Polypropylene. The internals are made from solid PE1000, and then a sturdy outer case made from ductile cast iron protects the pump from external forces and torques. The double mechanical seal ensures that there is limited risk of the product leaking from around the shaft. All metallic parts are protected using corrosion proof epoxy resin paints, which further increases the service life of the pump in aggressive chemical applications. The pumps were installed and laser aligned by our Site Installation engineers, and the units have run continuously since installation to the customer’s total satisfaction. For more information on how Pump Supply & Repair Group can assist you in your operational needs, please contact our Sales Team on 0161 864 4678, or via email on sales@pumpgroup.co.uk

Posted in Latest News, News

Pump Group Use Belzona to Repair 12m Screw Feeder

Pump Supply & Repair Group arranged transport of the 12m Screw Feeder from an EON Power Station Site. The unit was taken out of service because of extensive wear to flights & central tube. Non Destructive Testing was carried out on the flights, the shaft and the teeth. Ultra sonic testing determined the thickness of the worn 304 Stainless Steel Lining, and MPI Testing (Magnetic Particle Inspection) was used to identify cracks in the surface. In total, 326 faults were detected that required welding along the face of the screw, and in several areas the steel lining had worn down to less than 3mm thickness. The cracks were welded using hard face SS2333 rods to prevent future cracking. The teeth were substantially worn and several teeth were missing. All the teeth were removed and new teeth were welded on with 304 SS rods. The teeth were hard face welded on 2 sides using MAC Hard E306 rods to further increase their abrasive resistance.   The 10 ton screw was then grit blasted to SA 2.5 @ 75 microns to ensure correct surface profile for Belzona application.  Belzona 1812 Ceramic Carbide was applied to 15mm on the wear pads on the flights to build up to original thickness. Belzona 1812 was then applied at a thickness of 4mm to the shaft and all working faces of the screw & flights. The total job turnaround of the screw was 10 weeks from the go-ahead to completion. For more information on how Pump Supply & Repair Group can utilise our Belzona facilities and expertise, please contact our Operations Director, Martin Cooper on 0161 864 4678 or via email at mcooper@pumpgroup.co.uk

Posted in Featured Belzona, Latest News, News

Liquid Ring Vacuum Pump Repair – Food Industry

A team of our Site Services engineers attended site and carried out an endoscopic inspection on the Vacuum Pump.  After reporting on the findings, the decision was made for our site team to remove the unit and transport it back to our workshop facility for disassembly and further inspection. Upon stripping, it became apparent that there was substantial damage to the internals of the pump. The endplates and rotor were scored heavily. The gland seals were worn and the gland locations needed rebuilding. The bearings were stripped and condemned because of contamination. When measured, both bearing housings were oval shaped and outside tolerance. The pulley was found to be in poor condition and we recommended fitting new. The packing sleeves were grit blasted and rebuilt with Belzona 1131 Bearing Metal. We machined the rotor, the endplates, the body length and O-rings were machined to maintain the OEM tolerances. The damaged gland areas were rebuilt with Belzona 1131 and machined to size. The bearing housings were metal-sprayed and new bearings & consumables were supplied. A new pulley was supplied and fitted to prevent belt slippage.  The pump was assembled vertically to achieve correct clearance and then pressure tested. The unit was then fully performance tested in our test cell, and at 480mbar the pump achieved 9400m3/hr discharge volume.  The Pump was spray painted, and underwent final inspection prior to being transported back to site by our transport. Our site service engineers then installed and commissioned the unit. The unit was removed, refurbished, tested and installed and commissioned all within the time-frame allowed by the customer and within budget. As Rotating Equipment Specialists, Pump Supply & Repair Group is the one stop shop for all of your mechanical needs. For more information on how PSRG can assist you in your operational requirements, please contact our Operations Director, Martin Cooper at mcooper@pumpgroup.co.uk or on 0161 864 4678.

Posted in Featured Repairs, Latest News, News

Belzona Protects Trench From Acid Attack

The customer was experiencing problems within a 40 metre long trench near a tanker off-loading area. Tankers carrying both Sulphuric and Nitric acid were being emptied regularly, with small amounts of acid being spilled each time. This acid had corroded through large areas of the concrete floor and trench, and there was a danger of the acid corroding through the remaining concrete and contaminating the underlying soil & water table. One of our specialist engineers attended site to survey the problem, and concluded that the extremely hard wearing yet versatile range of Belzona Polymeric Coatings would be ideal for this scenario.  The ability to apply the Belzona polymer coatings cold and the fast curing properties were ideal for this situation. Once given the instruction to proceed by the customer and all of the relevant Risk Assessments and Method Statements had been approved, a team of our factory trained Belzona approved technicians attended site to carry out the repair. They cleaned the concrete using high pressure steam cleaners, removing all traces of acids and oils to ensure the Belzona product bonded to the concrete substrate. First the technicians used Belzona 4141 Magma Build, a concrete specific repair polymer, to rebuild the concrete back to the original profile, then applied 2 coats of 4311 Magma CR1, which is a high performance coating designed to withstand the most aggressive chemical attacks. The Belzona process took our 2 engineers 8 days from start to finish, which is a lesser period than how long it would have taken to concrete the damaged areas, which would have also needed 28 days to cure. The 4311 Magma CR1 has many times the chemical resistance of concrete, meaning that the Belzona repair will far outlast any traditional repairs that could have been used. For more information on how Pump Supply & Repair Group can utilise Belzona Coatings both in our workshop and on-site, please contact our Site Services Manager, Charles Lambley, on 07887 721900, or email him on clambley@pumpgroup.co.uk

Posted in Featured Belzona, Featured Site Work, Latest News, News Tagged , , , , , , , , ,

Protected: Screw Feeder Repaired With Belzona

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On Site Equipment Installation

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On Site Vacuum Testing

Vacuum Pump Testing, Condition Monitoring, Laser Alignment and Endoscope Inspection Recently Pump Supply & Repair Group were asked to attend the site of a Power Station in London to perform a vacuum test on two Nash pumps. In addition, our scope of work involved confirming the alignment the pump/motor using laser equipment, checking the vibration & bearing noise using condition monitoring equipment and inspecting the internal condition of the pump using an endoscope probe. Our testing procedure involves fitting orifice test flanges, each with 18 precision cut ‘test holes’. A vacuum test gauge is attached to the centre of the plate to record pressure during the blanking off of each test hole in turn.The performance of the pump was determined by the application of mathematical formulae using the results recorded. A graph is then produced comparing the performance with the OEM catalogue curve, as can be seen in this image. The graph shows that below 16″ Hg, the pump is performing at approx 90% of its original specification, however, above 16″ Hg performance detoreriorates rapidly, achieving only 36% at its duty point of 25″Hg. Further investigation using our endoscope probe revealed that there was significant disintegration and corrosion of the rotor vanes, particularly at the drive end of the pump. An example of this damage can be seen on the attached image, and this almost certainly contributed to the poor performance of the pump. Our laser alignment equipment indicated the pump to have remained in alignment in the vertical plane, however, it was marginally out horizontally: we proceded to ease the pump back into alignment, aided by the ‘live’ display given by our equipment which gives a continuously updated display of the alignment. The attached image shows the final alignment report.Our ultrasonic Condition Monitoring equipment indicated that vibration and bearing condition were all within accepted tolerances.Visual inspection also revealed on of the mechanical seals to be leaking. Our recommendation to our customer was to remove the pump from service as debris from the disintegrating rotor could enter the process causing damage throughout the system. Our overhaul of the pump would involve Belzona coating to protect surfaces liable to the effects of corrosion and using Belzona to rebuild the profile of the rotor. As a matter of course, bearings and mechanical seals would also be changed. For further information or to discuss any testing requirement you may have, please contact: Site … Continue reading

Posted in Featured Site Work, Homepaged Feature Article, Latest News, News