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 firstname.lastname@example.org
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 email@example.com.
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
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 firstname.lastname@example.org.
GOOD ENGINEERING KNOWLEDGE & SKILLS REQUIRED ROTATING EXPERIENCE PREFERENTIAL WORKING TO TOLERANCES ABILITY TO WORK INDEPENDENTLY GOOD WRITTEN/VERBAL COMMUNICATION SKILLS CONTACT JOY ON 0161 864 4678 OR BY E-MAIL
Industry – UK Nuclear Power Generation A nuclear power station producing 1000 MW requires in the region of 150,000 m3 of cooling water per hour when active. The flow is regulated by the Main Cooling Water (MCW) Valves, which throttle the supply. As a result of this duty, the valves can be damaged by the effects of the constant water flow & cavitation. The client had removed 4 of these 66” MCW valves and sent them to Pump Group for refurbishment. The butterfly valves had previously been coated by others, and it was clear to see that there was extensive damage to the valve. Pump Group had previously used Belzona® 2141 Anti-Cavitation polymer to coat the pipes immediately downstream of the valve; as the client was happy with the performance of the Belzona they elected to use it on the valves. On arrival the valves were disassembled and inspected fully. The pressure side of the valve was worn but in reasonable condition, however the downstream side had suffered major cavitation damage. The existing coating had worn away completely near the leading edge, allowing substantial damage to occur to the metal due to the Corrosion – Erosion cycle. The existing coating was fully removed in our workshop then the base metal was hot chemical washed prior to being grit blasted. Once the surface profile was grit blasted to surface preparation specification SA 2.5 (75 micron surface profile), the metal was then tested to ensure salts and nitrates present were less than 3ppm concentration. This is to ensure that the Belzona polymer bonds correctly to the substrate correctly. Belzona® 1111 Super Metal was used to rebuild the severely worn areas to the original profile. On the upstream side, 4 x 250 micron coats of Belzona® 1321 Super Metal were applied. This side of the valve doesn’t have to be protected from cavitation, so a coating was selected to increase efficiency, whilst still offering long lasting protection against erosion/corrosion from the sea water. Another advantage of 1321 is that it has very high compressive strength, making it ideal for use on the upstream side of the valve. On the non-pressure side, 3 x 1000 micron coats of Belzona® 2141 ACR-Fluid Elastomer coating were used. The high elasticity of this polymer is perfect for combatting cavitation; nullifying the damaging effects from the shockwaves created by the collapsing bubbles. In addition to the Belzona coatings, … Continue reading
Industry – Food Production One of our external sales team attended a food production site at the request of the client to investigate their boiler feed system pumps. Our engineer identified that the horizontal multistage pump was oversized for the requirements of the boiler, causing system problems, high operating costs and consequently consuming too much power. Our engineer calculated that the needs of the system would be best met by installing an intelligent booster set which could alter performance as and when needed to minimise energy usage. PSRG specified a booster set containing 4 off 5.5kW Lowara SV vertical multistage pumps with variable speed drives and pressure vessels. The booster set is driven by an intelligent control system which utilises various pressure transducers to determine the number of pumps that are running, and at what speed they are running at. This means that the necessary pressure is always maintained, but energy isn’t wasted due to excess pumping. The system has been specified so that annual need of the boiler can be met by 3 of the 4 pumps running for 100 hours. The system was installed and commissioned by our own team of Site Engineers out of production hours. Given a calculated cost saving of over £3,200 per year, the new installation will have a payback period of less than 5 years – including installation and commissioning costs. If you have any requirements for any new pumps or parts, please contact our Sales Team on 0161 864 4678 or via email@example.com
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 firstname.lastname@example.org