Monthly Archives: January 2015

Performance Test of Split Case Pump for Oil & Gas Client

The 3 tonne Weir Medivane 10/12” ZSB Split case pump  had undergone a  refurbishment by the Manufacturer and Pump Group were contacted to carry out full performance testing prior to re-installation offshore. The unit is used on Sea Water Injection (SWI) application on a North Sea platform and had been removed as part of a maintenance programme following experiencing problems with the cooling for the bearings/thrust pad.The unit had been fully refurbished and was scheduled to be departing Aberdeen Terminal on a specific ship in order to meet the production requirements of the platform. Pump Group  were initially given a 2 week window in which to facilitate the testing of the pump (including the fabrication of high pressure pipework & manufacturing of a coupling hub to fit the tapered pump shaft) which was subsequently reduced to less than a week. Pump Group Test Engineers had been in constant dialogue with the Clients’ Engineering Focal Point contact as the potential testing window shrank, and by the time it was made  apparent that the pump would only have a few days in Manchester for testing, all of the details necessary to have all of the necessary pipework/couplings manufactured had been taken. A counterflow heat exchanger was sourced to cool the oil during the 8 hour endurance test, and fittings were manufactured by Pump Group in-house to enable a seal flush system to be connected to the seal. The pump arrived on overnight transport from Aberdeen, the unit was set up in the Performance Test Cell (including hydrostatic pressure testing of the bearing lube oil system), LASER aligned and a preliminary test run was carried out prior to a representative from the client flying in on to witness the endurance test. The pump was ran for 8 hours, with bearing temperatures recorded throughout the duration of the test & condition monitoring results were taken several times using Pruftechnik VibXpert II system during the test to identify any vibration trends developing. Following the successful endurance test, the unit was removed from the Test Cell at 16.00, drained of all liquids and despatched that evening on overnight carrier for immediate delivery to Aberdeen. The completed oil cooling system & seal flush pipework was then connected & the pump was shipped offshore on Monday AM. For more information on how we can utilise our extensive workshop and testing facilities to assist your company with your operational … Continue reading

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Profile Recovery of Impeller using Weld & Belzona 1812 Ceramic Carbide

Our customer was experiencing issues with corrosion & erosion destroying their pump units on a Flue Gas Desulphurisation (FGD) application. Whilst purchasing the uprated impellers – made out of a more resistant Super Duplex, even then the impellers were lasting less than a year before the pumps needed removing from service for overhaul. The impeller was despatched to Pump Group with the aim of sourcing a more long term and cost effective solution rather than just replacing the impellers with new from the OEM.  Pump Group suggested rebuilding the impeller using specific Belzona Polymeric Coatings designed to withstand such damaging conditions. The impeller was bead blasted and jet washed clean, and metal inserts were fabricated to roughly rebuild the impeller profile. The inserts were then welded in to position and hard face welding carried out over the edges to increase the strength. The impeller was shot blasted to remove all possible contaminants and also to achieve a surface profile of SA2.5 @ 75microns which is required for the Belzona to bond correctly to the substrate material. The unit was then salt tested prior to coating to confirm the lack of presence of nitrates and other contaminants which can jeopardise the longevity of the coating. The surface was rebuilt using Belzona 1812 Ceramic Carbide.  Belzona 1812 was selected as it is a composite material combining extremely hard closely packed abrasion resistant ceramic aggregates in a polymeric binder ideal for the repair and protection of substrates being damaged by particle abrasion. Once the Belzona was applied (6mm thick) the impeller diameter and neck was machined with a diamond tipped tool to achieve required clearances within the pump. A mandrel was manufactured to allow the rotating element to be dynamically balanced to G2.5 at 1000 rpm. By utilising Belzona, the impeller was rebuilt in a much shorter period of time, approximately half the cost of a new impeller, and the Belzona 1812 Ceramic Carbide coated impellers achieves twice the life of the OEM impellers. For more information on how we can utilise our extensive Belzona knowledge and Coating 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 email repairs@pumpgroup.co.uk.  

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