PUMPS
LIFE STARTS AT 40
SULZER
40-YEAR-OLD REFINERY PUMP RECONDITIONED
AND RETURNED TO SERVICE
The normal life cycle for a hardworking and
crucial asset such as a boiler feed pump
is 20 years. However, a Sulzer BB3 pump
removed from a refinery in Argentina
has been given a new lease of life at
40. Rejuvenating legacy equipment is a
specialist field that needs considerable
expertise for a successful outcome.
The BB3 pump is one of the most widely
used high energy pumps in the world,
operating throughout the oil & gas industry
as well as the hydrocarbon sector. In this
case, one example was running as one of
a pair of boiler feed pumps in a refinery in
Argentina. The pump had to be taken out
of service at short notice and refurbished
quickly to ensure adequate capacity for the
boiler.
MINIMIZED DOWNTIME
The spare pump continued to operate but
the failed pump was sent as a critical repair
to enable it to return to active duty at the
earliest opportunity. This would minimize
any downtime and secure the reliable
service of the pump for years to come.
Sulzer regularly provides maintenance
services to the refinery and was one of the
first to be invited to submit a quote for the
inspection and subsequent repair of the
pump. Sulzer’s bid was accepted in the
main because of the price and the quality
that the company offers, but also because
of the speed with which such repairs can be
completed.
REPAIR ASSESSMENT
The pump, which had been in service for
more than forty years, was removed and
shipped to the service center in Buenos
Aires. The initial inspection revealed
damage to the pump body as well as
corrosion of the pump case. The shaft was
damaged and all the wear rings would also
need to be replaced.
The pump shaft was removed and
inspected in-house using non-destructive
testing (NDT) procedures and found to
be damaged beyond repair so it was
also replaced. These tests are crucial in
detecting structural flaws and in this case,
tests were conducted on all of the pump
components.
Once the full extent of the required repair
had been established, the casing walls
were rebuilt using a welding process
that adds a layer of material that can be
machined back to specifications. With the
welding complete, this section was again
inspected using NDT before the casing was
transferred to the machine shop where it
could be re-bored.
COMPREHENSIVE TESTING
In the meantime, the new pump rotor was
reassembled and balanced, while the wear
rings were replaced when the casing repairs
had been finished. The pump was put back
together before being hydro tested at 1.5
times working pressure. The test procedure
was designed and performed by Sulzer’s
engineers to ensure that pump was ready
to be reinstalled.
Throughout the repair project, constant
contact with the customer was maintained
explaining the findings and the proposed
resolutions. The customer was happy with
the quality of the work completed and the
attention to detail that ensured a robust
repair.
Esteban Obiglio, Sales Manager, at Sulzer
explains: “It is essential in any overhaul
project to deliver the best possible solution
and ensure the customer is kept up-to-
date. It is also important to understand the
expectations of your customer and make
every effort to deliver a cost-effective and
reliable repair.”
PLANNING FOR THE FUTURE
Throughout the project, the customer
frequently visited the service center to
review progress and discuss options for
the pump that remained in service, which
was a similar age and therefore facing
comparable issues with erosion and wear.
One potential solution, suggested by
the customer, was to replace the casing,
a project that could be completed in
approximately two weeks.
Esteban concludes: “The customer was
looking to the future and by discussing
possible solutions, was able to assess all the
options and make an informed decision.
The refurbished asset will provide cost-
effective and reliable service for many years
to come.”
For more information on Sulzer, visit
www.sulzer.com
Issue 42 PECM
123