Author Archives: Web Team

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

Posted in Featured Belzona, Latest News, News, Newsletter Tagged , , , , , ,

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

Posted in Featured Repairs, Newsletter, Test Tagged , , , , , , , , , , , , , ,

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

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

E.ON Grain Apprentice Completes 18 Week Industrial Placement at Pump Group

April saw Pump Group bid a fond farewell to Jack Thurlow, an engineering apprentice normally based out of EON Grain Power Station, Kent. Since November Jack has been seconded to Pump Supply & Repair Group for a work experience placement in pump engineering and to gain valuable rotating equipment knowledge. Jack started off working in the Disassembly Department, stripping and inspecting units to ascertain cause of failure. Following this he progressed to working in the Fitting Dept, shadowing experienced engineers as they assembled a wide range of pumps and other rotating equipment including: Liquid Ring Vacuum, Multistage, Split Case & Centrifugal Pumps. Jack also spent time within  the Performance Test Cell where he assisted in setting up and LASER aligning numerous pumps repaired in our workshop both surface mounted in addition to submersible units. This allowed him to witness how they are performance tested using thermodynamic test methods with the results compared against OEM test curves to ensure repaired units had achieved the performance targets criteria set. (See our Performance Test Cell page for more detail) Whilst at Pump Group Jack also undertook several training initiatives and has received certification in: – NSK Bearing Care & Maintenance – Grundfos Ecademy Pump Training – JA Harrisons in-house gasket training – Manual Handling & Slinging training “Jack is both very bright and quite motivated. He is a quick learner and has shown the ability to digest large volumes of information. Jack has become a well-rounded engineer apprentice who is well equipped to grow from challenges that he is presented with He has excellent written and verbal communication skills, is extremely organized, can work independently and is able to follow through to ensure that the jobs get done. I’m sure he will be one to watch out for in the future.” Samantha Hill – Production Manager

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

Belzona Repair of a Lined Acid Receiver – Chemical Industry

The Acid Receiver was removed from a chemical production site installation following customer concerns regarding the flange integrity and the receiver was transported  to Pump Group for repair. The tank has a metal shell lined with polypropylene and then wrapped with glass fibre.  Upon inspecting the tank, it became clear that both the PN16 Plastic flanges had been heavily corroded and were no longer safe to use in their current state. It appeared that acid had slowly leaked past the gaskets on both the flanges, and the acid had corroded through the glass fibre, the polypropylene and even the metal shell. Pump Group engineers proposed a course of action to remove the damaged flanges and rebuild new flanges using Belzona 1111 Super Metal.  Belzona 1111 was selected because it is a metal repair composite which has excellent adhesion to metals and plastics, meaning it can be used to both re-form the flanges and bond the flanges to the tank. The damaged flanges were cut off and the edges prepared by removing the glass fibre and polypropylene 2” back from the existing flanges and then grit blasting the necessary areas. A mild steel forming plate was manufactured and bushes welded on which had the same PCD and clearance hole size as the existing flanges. 2 split rings were manufactured our of 316 Stainless Steel which were located behind the flange faces. The flanges were then rebuilt with Belzona 1111 using the forming plate and split rings to ensure the correct size. Belzona 1111 was used to bond the rebuilt flanges to the tank, and the mould and split rings were released once the Belzona had cured. The OD of the Nozzles and flanges were coated with Belzona 1321 Ceramic Super Metal. Belzona 1321 is designed to provide corrosion resistance to surfaces – it has high chemical resistance which will prevent acid attack causing damage to the flanges should  leakage occur in the future. For more information on how we can utilise our extensive Belzona knowledge and Coating Facilites 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.    

Posted in Featured Belzona, Homepaged Feature Article, Latest News, News, Newsletter Tagged ,

Pump Group Commissions New Shot Blasting Facility – 20 Tonne Capacity

Late 2014 saw the commissioning of an £100,000 expansion project for Pump Group’s Belzona Coating business unit. The size of equipment being repaired by Pump Group has increased year on year, and the new shot blast cabinet recently commissioned is more than a match for the increase in shot blasting requirements. Pump Group was the UK’s first Belzona Approved Coating Centre and has strived to stay ahead of the competition in both experience, capabilities and facilities. In 2010 when Pump Group moved to a purpose built 32,000 sq ft facility the Belzona Application Room was doubled in size and now has full overhead crane access whilst maintaining a temperature and humidity controlled climate (atmosphere). The shot blast cabinet was fabricated to meet increased requirements and allow the operator to blast items up to 10m in length & 3m wide. It was designed with a mechanised bogie system which has a 20 tonne capacity. This means the operator can safely blast large impellers, casings and other components with ease. The cabinet utilises the latest sound attenuation methods which limit the environmental impact of the process and also improving the working conditions for the operator. The cabinet holds a large quantity of chilled iron grit which is blasted and recirculated by the Media Recovery Floor. This system constantly scrapes the abrasive & deposit from under grid beneath the operators feet and then filtered and recirculated automatically. This has greatly increased efficiency meaning an increase in throughput from the blasting team. Ian Pendleton of Pump Group had this to say: This investment has led to a more efficient process with a higher capacity which will be capable of meeting the ever increasing needs of our wide and varied customer base. This will allow us to pursue larger jobs requiring coating application. These brand new shotblasting facilities combined with our state of the art Coating Clean Room means that we are in a position to handle many more Belzona Coating contracts with an improved turnaround. For more information 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.    

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

Repair & Performance Test of a 26/24″ Vertical Split Case Pump

The 6 tonne Mather & Platt 26” / 24” Lonovane Split case pumps were removed from site after failure, and sent to Pump Group with the remit of carrying out a full overhaul and performance test. The units are used on site at a Coal Fired Power Station drawing water out of the nearby river to be filtered and then used as cooling water for the power generation process. The site normally has 4 pumps installed including one standby. Two of these pumps had both failed within a short period of time meaning that the site was close to a shutdown scenario should anything happen to either of the remaining units. On receipt at our works the units were cleaned and disassembled and the causes of failure determined. On one unit the shaft had sheared and on the other the upper thrust bearing had failed. On both units this meant the rotating element was able to drop and therefore impact and run against the lower neck ring. The seal mounting sleeves, roller bearings & intermediary make-up sleeves were all damaged beyond a repairable state. New parts were reverse engineered in-house out of Stainless Steel. The mechanical seals were also replaced with new. Several areas including the cutlass bearing holder and the bottom housing were also rebuilt with Belzona 1111 (Super Metal) which was then machined to size. Belzona Polymer 1111 is a solvent free epoxy resin reinforced with silicon steel alloy which makes it ideal for this application.This was a quicker and more cost effective alternative to completely reverse engineering the damaged areas. New shafts were machined from EN24T and the impellers were re-ringed to reduce the wear ring clearances to within tolerance. The rotating element was then built and dynamically balanced to G2.5 at 1000rpm. After assembly, the unit was hydrostatically tested to 1.5 times working pressure. The units are be run in a vertical orientation on site so to enable testing a motor stool plate was manufactured to allow one of the test stock 250 kW motors to drive the pump. A motor stand to support the weight of the motor was also fabricated and used on test. The unit was placed in our Performance Test Cell, laser aligned to one of our 250 kW motors and performance tested. The units underwent detailed vibration analysis using Pruftechnik VibExpert system and a performance test report was produced and issued to … Continue reading

Posted in Featured Repairs, Homepaged Feature Article, Latest News, News, Newsletter Tagged , ,

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

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