Yearly Archives: 2014

Newsletter Spring 2014

  Please see our Spring 2014 newsletter here.   If you were not a recipient of this newsletter and would like to be kept in touch, please click the ‘Subscribe’ button below!

Posted in Homepaged Feature Article, News, Newsletter, Uncategorized

Contract Labour – Pump Group Engineers Assist With Shutdown At Petrochemical Refinery

Industry – UK Oil & Gas Refinery As part of our contracts with clients, Pump Group has qualified technicians providing full-time specialist assistance in several industries across the UK. One of our client’s sites, a petrochemical refinery capable of producing 300,000 barrels per day, recently underwent a major shutdown and asked Pump Group to assist. For the duration of the shutdown, our client required eight Pump Group rotating equipment engineers on-site to carry out essential maintenance and modification to their plant. Don’t think that we are just a pump company  –  the client was able to utilise our extensive experience with repairs on all types of rotating equipment, working on several key projects including the Aromatics Raffinate Wash Water Column, Fin-Fan cooling systems, Rotary Vacuum Filters & physical isolation of plant and pipework. Many of the work scopes included confined space and Breathing Apparatus work. Our engineers were able to rely on our facilities when in-situ repairs weren’t possible; several items were transported to our workshop to have fabrication, machining work carried out & Belzona® Coatings applied. A number of pumps were also removed and performance tested in our Test Cell. Several issues were identified through Vibration Analysis allowing necessary repairs to be undertaken, minimising the chance of unplanned downtime through failure in service. For more information on how our team can provide assistance with your planned (and unplanned!) shutdowns, please contact our office on 0161 864 4678 or by emailing repairs@pumpgroup.co.uk

Posted in Featured Contract Labour, Latest News

Crude Oil Booster Pump – 60Hz Performance Test For North Sea Oil & Gas Client

Industry – Oil & Gas A Crude Oil Booster Medivane Split Case pump was suffering operational issues where it was installed offshore. The pump was removed by the operator and returned to the OEM for overhaul. We were contacted by the pump OEM to test the performance of the unit post refurbishment ahead of its return to a North Sea Oil Field installation within a 2 week window. Inside this timescale the unit was installed & Laser Aligned in Pump Group’s test facility, commissioned ahead of testing, operated during a 4 hour Customer Witnessed Test Session to confirm performance at the site operating conditions. The test circuit was artificially heated and maintained to 50°C for the duration of the test. We also utilised our positive pressure system to provide an additional 0.5 bar pressure to the suction tank, and our installed duplex filter system allowed us to carry out the extended duration test whilst keeping the filters clear. In addition to the pump performance test report, a mechanical report was prepared which included the bearing temperatures recorded throughout the duration of the test, and once the pump temperatures had stabilised, condition monitoring readings were taken using Pruftechnik Vibscanner equipment and a detailed vibration analysis report was issued. The test was only made possible by the support of Pump Group’s manufacturing and fabrications teams, allowing in-house modifications to critical components during the installation and setup. Following testing the unit was returned to the North Sea installation and has been successfully installed and is in now in operation. Working to such a critical deadline Pump Group was able to rely on strong working relationships with key suppliers to source parts required for testing from across the UK and Europe, with a coupling being sourced from John Crane in Czech Republic, couriered to Pump Group in Trafford  and machined, all within 48 hours, to allow testing to be completed on schedule. Further to the successful completion of this testing for the Pump OEM, Pump Group have just received confirmation of more orders for Performance Testing in the coming weeks. For more information on our Performance Test Cell, or to discuss how our test facilities can be of use to you, please contact our Test Manager James Pendleton-Briers on 0161 864 4678 or via jamespb@pumpgroup.co.uk.  

Posted in Featured Repairs, Homepaged Feature Article, Latest News, News, Test

Critical Turnaround 350kW Fan Repair & Test

Industry – UK Flooring Manufacturer Our client reported concerns on operations of a large extraction fan, one of our External Sales Engineers attended site to assess the situation & take condition monitoring readings which confirmed vibration was at unacceptable levels and advised that the unit was removed for overhaul. The unit is the sole extraction fan weighing 5 tonnes for a flooring production factory which couldn’t operate safely without the fan in use. The plant was therefore shutdown until the fan could be reinstalled. The Condition Monitoring analysis determined that both the motor and fan bearings were not showing any signs of damage – the vibration was propagating from the impeller end of the fan. Given the criticality and short timescale of the repair, the overhaul of the rotating element was undertaken to cure the vibration issue. The fan was delivered to our workshop facility and the front cover was removed to find that the impeller was fractured on the front shroud. Closer inspection identified further cracking and fractures on the impeller vanes. The impeller was separated from the shaft, pressure cleaned prior to MPI testing. Magnetic Particle Inspection was carried out on the impeller which located over 80 further faults to the welds & blades of the vanes. All cracks were then terminated by a drilled hole to stop the crack from propagating prior to the welding of the blades.  The rotating element was then dynamically balanced to G2.5 @ 1450rpm. The impeller was re-drilled and the covers were refitted with a new seal which had been specified to suit the 250 °C operating temperature. The unit was painted internally & externally, the fan reassembled & the unit placed in our test cell where the motor & fan shafts were LASER Aligned to minimise vibration. The 350kW motor was connected to our Control Panel Inverter and the unit was run up to full speed witnessed by our client. Once bearing temperatures had stabilised full condition monitoring results were taken. Vibration had reduced from RMS values of over 10mm/s to below values below 1.5mm/s. The time taken from the unit arriving in our workshop to it being back on site was less than 3.5  days. After delivery of the fan to the clients premises, our engineers attended site to carry out Laser Alignment of the fan drive to the motor before the unit was commissioned. The unit has run on site … Continue reading

Posted in Featured Repairs, Latest News, News

6.5 Tonne Split Case Pump Repair for Chemical Plant

Industry – Chemical Production Two 6.5 tonne Mather & Platt 28” / 22” Split case pumps were removed from site as part of planned maintenance, to carry out a complete overhaul. All bearing, shaft diameters and housings were checked and found to be within tolerance for their respective class of fit. The white metal bearings were re-lined for re-use. Further out from the journal diameters there were deep marks due to action from the seals and baffle plates.  We undercut the markings and rebuilt with Belzona 1131 Bearing Grade® polymer and machined to OEM specifications. Damage from Off-Axis running was present in both DE & NDE Bronze bearing shells. This was remedied by white metal lining the shells then boring to original dimensions. The top & bottom halves of the volutes were generally in good condition, but with internal surface scaling present.  The internals were grit blasted to surface profile specification SA2.5 and 2 coats of Belzona 1341 Supermetalglide® were applied. Belzona 1341 Supermetalglide® was selected as it improves pump efficiency by using hydrophobic technology to repel process fluids and reduce turbulent flow, lowering energy costs. The units underwent seal conversions top AES Split Cartridge Seals with Silicone Carbide running faces and LabTecta® Push-Fit bearing protectors. The Stainless Steel impeller was in good condition with only superficial markings. The impeller was dynamically balanced at 1000rpm to G2.5 prior to reassembly. After assembly, the split case pump was hydrostatically tested to 1.5 times working pressure and was placed in our Performance Test Cell, laser aligned to one of our slave motors and performance tested. The units underwent detailed vibration analysis using Pruftechnik VibExpert system and a performance test report was produced and issued to the customer. The units had been made redundant several years earlier, and had been sat dormant since then. Plant cooling water requirements changed and Pump Group were able to refurbish and modernise the pumps within the clients’ budget.  The unit was returned to site within the allowed time frame to meet customer requirements. For more information on how we can utilise our extensive workshop and testing facilities to assist your company with your operational needs, please contact a member of our Repairs Team on   +44 (0)161 864 4678 or via repairs@pumpgroup.co.uk.

Posted in Featured Belzona, Featured Repairs, Homepaged Feature Article, Latest News, News