Sulzer pump experts suggested an approach that could save its customer time and money .
MORE COST-EFFECTIVE SOLUTION Since the existing pump was a Sulzer unit , the team initially asked the global pump specialist to quote for two new pumps capable of meeting the revised operating requirements . They explained that they needed one working pump and another in reserve , allowing periodic exchange for maintenance and repair . That conversation led Sulzer pump experts in Singapore to propose an alternative approach that could save its customer time and money .
After visiting the site to examine the customer ’ s existing spare pump , Sulzer confirmed that it could make selective upgrades to the original pumps , then test and re-certify them to comply with the new 45 bar MAWP and all relevant reserve and safety factors .
Once the plan was agreed , the spare pump was transferred to a Sulzer engineering facility in Singapore , where it was stripped down for analysis . Since the pump had spent time in service , it was exhibiting all the usual signs of a hard working life , including extensive corrosion to wear parts such the impellers . Sulzer ’ s team of pump experts identified several components
for replacement and subjected the remaining parts to detailed inspection including dye penetrant testing ( DPT ).
SELECTIVE UPGRADES In parallel , Sulzer engineering specialists designed a new caisson with thicker walls , to cope with the higher working pressure , and upgraded material , to provide improved corrosion resistance . They also rerated the seal system to cope with the new operating parameters .
The new seals , caisson and other replacement parts were manufactured at a specialist Sulzer facility in Germany , then shipped to Singapore where the pump was reassembled , hydro tested and certified for the higher MAWP . The completed pump was installed and commissioned by Sulzer field engineers at the customer ’ s site .
FAST , SAFE AND SURE The entire upgrade process took only six months to complete . That allowed the company to stick to a tight schedule for its overall plant revamp project . As an additional benefit , the cost of the re-rate project was significantly lower than the cost of two new replacements by USD 200 ’ 000 . With the original pump now in operation , the Sulzer team has since completed the same set of upgrade tasks on the customer ’ s second unit .
As process plants grow and evolve , it is common for the operating requirements of critical equipment to change . To maintain safety and ensure long-term reliability , it is vital that such changes , especially pressure increases , do not push components beyond their certified limits .
Sulzer ’ s pump diagnostic , upgrade , retrofitting and maintenance services , backed by its knowledge as a leading OEM , allow customers to extend the capabilities of their equipment , with the confidence that every unit has all the necessary testing and documentation to detail the changes made and provide proof of safe operation . Furthermore , by choosing the retrofit solution instead of installing new machinery , the carbon footprint of the project was minimized , supporting the sustainability aims of the customer .
For more information , visit www . sulzer . com
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