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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 firstname.lastname@example.org.
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 email@example.com.
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 firstname.lastname@example.org
Vacuum Pump Testing, Condition Monitoring, Laser Alignment and Endoscope Inspection Recently Pump Supply & Repair Group were asked to attend the site of a Power Station in London to perform a vacuum test on two Nash pumps. In addition, our scope of work involved confirming the alignment the pump/motor using laser equipment, checking the vibration & bearing noise using condition monitoring equipment and inspecting the internal condition of the pump using an endoscope probe. Our testing procedure involves fitting orifice test flanges, each with 18 precision cut ‘test holes’. A vacuum test gauge is attached to the centre of the plate to record pressure during the blanking off of each test hole in turn.The performance of the pump was determined by the application of mathematical formulae using the results recorded. A graph is then produced comparing the performance with the OEM catalogue curve, as can be seen in this image. The graph shows that below 16″ Hg, the pump is performing at approx 90% of its original specification, however, above 16″ Hg performance detoreriorates rapidly, achieving only 36% at its duty point of 25″Hg. Further investigation using our endoscope probe revealed that there was significant disintegration and corrosion of the rotor vanes, particularly at the drive end of the pump. An example of this damage can be seen on the attached image, and this almost certainly contributed to the poor performance of the pump. Our laser alignment equipment indicated the pump to have remained in alignment in the vertical plane, however, it was marginally out horizontally: we proceded to ease the pump back into alignment, aided by the ‘live’ display given by our equipment which gives a continuously updated display of the alignment. The attached image shows the final alignment report.Our ultrasonic Condition Monitoring equipment indicated that vibration and bearing condition were all within accepted tolerances.Visual inspection also revealed on of the mechanical seals to be leaking. Our recommendation to our customer was to remove the pump from service as debris from the disintegrating rotor could enter the process causing damage throughout the system. Our overhaul of the pump would involve Belzona coating to protect surfaces liable to the effects of corrosion and using Belzona to rebuild the profile of the rotor. As a matter of course, bearings and mechanical seals would also be changed. For further information or to discuss any testing requirement you may have, please contact: Site … Continue reading
This month sees the next exciting stage of growth for our Group, we have now moved to our new purpose built premises, CP House, in Trafford Park, Manchester, doubling our premises space to 32,000 ft2.