Crude Oil Booster Pump – 60Hz Performance Test For North Sea Oil & Gas Client

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 jamespb@pumpgroup.co.uk.  

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

Critical Turnaround 350kW Fan Repair & Test

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

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6.5 Tonne Split Case Pump Repair for Chemical Plant

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 repairs@pumpgroup.co.uk.

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

Nuclear Power Main Cooling Water Valves Get The BELZONA® Treatment

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

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Lowara Booster Set – New Sales

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 sales@pumpgroup.co.uk

Posted in Featured Sales, Homepaged Feature Article, Latest News

Rheinhütte Pumps Solve Customer’s Corrosion Problems

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 sales@pumpgroup.co.uk

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Pump Group Use Belzona to Repair 12m Screw Feeder

Pump Supply & Repair Group arranged transport of the 12m Screw Feeder from an EON Power Station Site. The unit was taken out of service because of extensive wear to flights & central tube. Non Destructive Testing was carried out on the flights, the shaft and the teeth. Ultra sonic testing determined the thickness of the worn 304 Stainless Steel Lining, and MPI Testing (Magnetic Particle Inspection) was used to identify cracks in the surface. In total, 326 faults were detected that required welding along the face of the screw, and in several areas the steel lining had worn down to less than 3mm thickness. The cracks were welded using hard face SS2333 rods to prevent future cracking. The teeth were substantially worn and several teeth were missing. All the teeth were removed and new teeth were welded on with 304 SS rods. The teeth were hard face welded on 2 sides using MAC Hard E306 rods to further increase their abrasive resistance.   The 10 ton screw was then grit blasted to SA 2.5 @ 75 microns to ensure correct surface profile for Belzona application.  Belzona 1812 Ceramic Carbide was applied to 15mm on the wear pads on the flights to build up to original thickness. Belzona 1812 was then applied at a thickness of 4mm to the shaft and all working faces of the screw & flights. The total job turnaround of the screw was 10 weeks from the go-ahead to completion. For more information on how Pump Supply & Repair Group can utilise our Belzona facilities and expertise, please contact our Operations Director, Martin Cooper on 0161 864 4678 or via email at mcooper@pumpgroup.co.uk

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Liquid Ring Vacuum Pump Repair – Food Industry

A team of our Site Services engineers attended site and carried out an endoscopic inspection on the Vacuum Pump.  After reporting on the findings, the decision was made for our site team to remove the unit and transport it back to our workshop facility for disassembly and further inspection. Upon stripping, it became apparent that there was substantial damage to the internals of the pump. The endplates and rotor were scored heavily. The gland seals were worn and the gland locations needed rebuilding. The bearings were stripped and condemned because of contamination. When measured, both bearing housings were oval shaped and outside tolerance. The pulley was found to be in poor condition and we recommended fitting new. The packing sleeves were grit blasted and rebuilt with Belzona 1131 Bearing Metal. We machined the rotor, the endplates, the body length and O-rings were machined to maintain the OEM tolerances. The damaged gland areas were rebuilt with Belzona 1131 and machined to size. The bearing housings were metal-sprayed and new bearings & consumables were supplied. A new pulley was supplied and fitted to prevent belt slippage.  The pump was assembled vertically to achieve correct clearance and then pressure tested. The unit was then fully performance tested in our test cell, and at 480mbar the pump achieved 9400m3/hr discharge volume.  The Pump was spray painted, and underwent final inspection prior to being transported back to site by our transport. Our site service engineers then installed and commissioned the unit. The unit was removed, refurbished, tested and installed and commissioned all within the time-frame allowed by the customer and within budget. As Rotating Equipment Specialists, Pump Supply & Repair Group is the one stop shop for all of your mechanical needs. For more information on how PSRG can assist you in your operational requirements, please contact our Operations Director, Martin Cooper at mcooper@pumpgroup.co.uk or on 0161 864 4678.

Posted in Featured Repairs, Latest News, News

Belzona Protects Trench From Acid Attack

The customer was experiencing problems within a 40 metre long trench near a tanker off-loading area. Tankers carrying both Sulphuric and Nitric acid were being emptied regularly, with small amounts of acid being spilled each time. This acid had corroded through large areas of the concrete floor and trench, and there was a danger of the acid corroding through the remaining concrete and contaminating the underlying soil & water table. One of our specialist engineers attended site to survey the problem, and concluded that the extremely hard wearing yet versatile range of Belzona Polymeric Coatings would be ideal for this scenario.  The ability to apply the Belzona polymer coatings cold and the fast curing properties were ideal for this situation. Once given the instruction to proceed by the customer and all of the relevant Risk Assessments and Method Statements had been approved, a team of our factory trained Belzona approved technicians attended site to carry out the repair. They cleaned the concrete using high pressure steam cleaners, removing all traces of acids and oils to ensure the Belzona product bonded to the concrete substrate. First the technicians used Belzona 4141 Magma Build, a concrete specific repair polymer, to rebuild the concrete back to the original profile, then applied 2 coats of 4311 Magma CR1, which is a high performance coating designed to withstand the most aggressive chemical attacks. The Belzona process took our 2 engineers 8 days from start to finish, which is a lesser period than how long it would have taken to concrete the damaged areas, which would have also needed 28 days to cure. The 4311 Magma CR1 has many times the chemical resistance of concrete, meaning that the Belzona repair will far outlast any traditional repairs that could have been used. For more information on how Pump Supply & Repair Group can utilise Belzona Coatings both in our workshop and on-site, please contact our Site Services Manager, Charles Lambley, on 07887 721900, or email him on clambley@pumpgroup.co.uk

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On Site Vacuum Testing

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

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