Monthly Archives: July 2015

Pump Group Extend Life of Power Station Pipework Using Belzona 1812 Ceramic Carbide

Pump Group were contacted to assist with an issue at a Coal Fired Power Station where the site engineers had sections of pipework which were failing within an unreasonably short period of time. The pipes are situated in part of the FGD (Flue Gas Desulphurisation) Plant part of the power station, which operates to remove harmful chemicals from the exhaust gases from the power station, specifically Sulphur Dioxide (SO2). The gasses are passed through a limestone slurry which ‘scrubs’ the SO2 from the gasses emitted. A direct product of this process is that Calcium Sulphate (CaSO3) and CO2 are created. The limestone slurry, now containing Calcium Sulphate is then pumped away for further treatment. This slurry is highly abrasive (due to the limestone) and very corrosive (due to the Calcium Sulphate), which means it wears away at pumps & pipework very quickly – the average lifetime of the pipes had been less than 6 months before pipes would need to be replaced with a new one. Pump Group engineers recommended coating with Belzona 1812 – Ceramic Carbide to provide a pipe interior which would outlast the poor performing existing pipes. To reduce the application time & to increase accuracy, Pump Group fabricators manufactured a flanged mould with a machined insert. This mould is then bolted onto the pipe prior to coating, and allows the technician to completely fill all spaces with Belzona 1812 uniformly whilst ensuring the internal dimensions are to specification. The wetted areas were 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 successfully to the substrate material. The pipes were then salt tested to confirm acceptable levels of nitrates and other contaminants which can jeopardise the longevity of the coating. The internal surfaces of the pipes were coated using Belzona 1812 Ceramic Carbide around the .  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. Following Belzona 1812 being applied on the pipes, the pipe flange faces were then final machined true using a diamond tipped tool. Pump Group had already carried out similar Belzona applications for the same client on the FGD plant and the client had seen a 50% increase in … Continue reading

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2014: Yet Another Year with No Incidents

As one of the UK’s largest Independent Rotating Equipment Specialists, Pump Group are called to assist clients with all manner of jobs both nationally & internationally. Due to the very nature of On-Site work, our technicians are often working in unfamiliar & hazardous environments, carrying out technically & physically demanding work. In the last 12 months alone our on site engineers have carried out the following varied site work assignments: Compressor Overhaul on F.P.S.O. in the Niger Delta, West Africa Reinstallation of Cooling Water Pumps for UK Power Station following repair & test by Pump Group Removal & Repair of 38 Tonne Sea Water Lift Pump for Power Station, Ireland Repair Contract for Main Inlet Valves for Hydro Electric Power Station, Ireland Ongoing Maintenance contract for personnel at Oil & Gas Refinery, UK Condition Monitoring & LASER Alignment Contracts on North Sea Platforms & F.P.S.O’s Vacuum Testing & Endoscopic Inspection on Rotary Equipment for Power Stations, South East UK Mechanical Seal Removal & Reinstallation Projects at Power Stations, UK Borehole Pump Removal & Installations across the UK Numerous Pump Removal & Installations for all industries across the UK Our site engineers have spent over 10,000 man hours last year working in demanding locations across the globe without any incidents. This achievement reinforces our company goal that Health & Safety of our personnel is number one priority at all times and our engineers can get the job done whilst working safely and professionally/proficiently.   For more information on our Site Services, please speak contact one of our Site Team on 0161 864 4678, or by email sales@pumpgroup.co.uk  

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

Performance Test of Fire Pump for Offshore North Sea Installation

The SPP 18HXB pump is installed on a Oil Drilling & Production Platform 120 miles off Aberdeen in the North Sea.  On the platform the unit operates as a Fire Pump, meaning that the when called upon, effective operation of the pump is critical. The pump was removed from site as part of scheduled maintenance programme, overhauled by the OEM and Pump Group were contracted to carry out a witnessed Performance Test of the unit prior to re-installation offshore. As the whole unit wasn’t removed from the platform, Pump Group had to source the following to facilitate the testing: Headpiece & Discharge Bend Mechanical Seal & Housing Bearing Assembly Bearing Cooling Pipework Headshaft with Sleeve & Bearing Housing Lock Nuts As the site motor was still offshore, a suitable slave motor was selected from PSRG Test stock, in this case being a 1490rpm 250kW flange mounted motor. Prior to the pump arriving at Pump Group premises, our in-house fabricators made a bespoke adaptor piece to connect the test motor to the sourced headpiece. On site the pump has several ‘riser pieces’, which are straight lengths of pipe between the discharge bowls and the discharge head, combining to give tens of metres of pipe between where the water is being lifted from and the motor/discharge head.  To ensure that the operations engineers could calculate exactly what discharge pressure would be available on site, they specified that Pump Group connected pressure tappings directly after the final pump bowl – before any rising pipe – see below image.   On arrival at Pump Group premises, the pump was installed in the test cell below ground tank, LASER Aligned using Pruftechnik Optalign Smart RS ©  equipment, and discharge pipework was fitted including throttling valve & calibrated 10″ flowmeter. Representatives from the client and the Platform Operator attended our site to witness the testing . The pump was run up to speed and a full performance curve was taken from closed valve to the max flowrate. Condition monitoring readings were recorded using Pruftechnik VibXpert II Dual Channel system, and the vibration spectra were reviewed by the client’s engineers. Bearing temperatures were logged throughout the duration of the test using a FLIR T420 Thermal Imaging Camara  connected to data acquisition software on a laptop. The engineers selected several specific “spots” on the pump & motor, and the software then plotted the temperature trends showing the ΔT … Continue reading

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Pump Group Engineers Now Armed With FLIR Thermal Cameras

Pump Group has taken receipt of the newest FLIR T420 Thermal Imaging Camera, to assist our engineers with various tasks – both on site and in our in-house Test Cell. Thermal Camera use allows the operator to identify machine faults quickly and safely using non contact methods – meaning that plant & machinery doesn’t need to be shut down or isolated for the survey to be carried out. Thermal imaging surveys can be carried out periodically without interfering with plant, and as temperatures of mechanical components increase as they wear, thermal imaging surveys allow our engineers to detect any change in the running temperatures and the high resolution screen pinpoints the source of the heat which indicates the source of the wear. Thermal Imaging Targets: Pump & Motor Bearing Housings Fans & Compressors Seal Flush Systems Gland Packing Motor Leads Electrical Control Panels Belt Drives & Conveyor Belts Advantages of using Thermal Imaging Cameras: Safe to use – non contact Unobtrusive – no need to shut down machinery, reducing down time Quick – no need to wait for panels to be isolated to carry out the survey Accurate – can quickly scan and measure temperature distribution of surfaces of machinery & electrics under normal working conditions     Thermal Imaging is now used in our In-House Performance Test Cell, where our engineers take thermographic  images of the unit once the unit is up to temperature. This data is then saved with our Vibration Analysis data giving an overall base line for the condition of the unit post repair.     If you would like to discuss a potential thermographic survey, or wish to find out more about how Pump Group can utilise these modern techniques to reduce downtime and reduce maintenance costs, please contact a member of our team on +44 (0)161 864 4678 or by emailing sales@pumpgroup.co.uk    

Posted in Homepaged Feature Article, Latest News, News, Newsletter

Performance Test on Fire Fighting System Deluge Valves for U.A.E. Oil Platform

In June 2015 Pump Group were contracted to carry out Factory Acceptance Testing (FAT) by a valve manufacturer on a batch of deluge valves prior to their installation on an Oil Platform situated off the coast of Abu Dhabi (U.A.E.). Deluge valves are an integral part of Fire Protection Systems located in high risk areas such as Offshore Platforms and Oil Refineries. They are designed to be installed into the Deluge Sprinkler System and as soon as a fire is detected the deluge valve actuates and allows a massive volume of water to surge through to the sprinkler heads. The deluge valves are unlike normal mechanical valves in that they use pressure differentials across the valve and the flow of water to fill a kevlar bag inside the valve which then, due to the unique shape of the internals, uses the water pressure to hold the valve shut. The Platform Operator specified that full performance testing of the valves had to be carried out at substantial flowrates across a range of inlet pressures replicating any possible site conditions that the valves may be required to operate under. The valves had to be tested to check that they could fully actuate open and closed at pressures of up to 15 bar. In addition to this, hydrostatic tests were carried out on the valves to ensure the integrity of the units. A test system was designed using our 250kW 2900rpm motor and a suitable split case pump was selected – capable of 19 bar pressures at flows in excess of 300 m3/hr. Valves were required up & downstream of the deluge valve being tested to allow engineers to carry out hydrostatic tests directly after the hydrodynamic flow tests. Representatives from both the Valve Manufacturer and the Platform Operator were in attendance for the testing of the valves – 6″ and 8″.  Pump Group Engineers performance tested the 8″ valve first: pneumatically actuating it open and closed at a range of pressures up to 15 bar, and then hydrostatically testing the valve to the required 19.5 bar. Using variable speed inverter drives in tandem with an additional gate valve downstream of the deluge valve, Test technicians were able to achieve a range of pressures from 5 – 15 bar all at the same flowrate by adjusting the pump speed and throttling the discharge valve. The 8″ valve was then replaced by the 6″ … Continue reading

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