An LPG system appeared in critical conditions of corrosion and wear at an advanced stage. As a result, it was necessary to carry out the improvement maintenance with the revamping of all the piping and the replacement of new generation pumps and motors. In this way the plant has returned to being efficient, competitive and sustainable. The advantages of the customer are different among which: maximum safety and environmental protection and ancillary activities, heritage conservation, high availability of the plant, improved maintainability, spare parts immediately available.
Reverse Engineering
Service Pumps Solutions offers, among its main services, the activity of Reverse Engineering, which consists in the accurate analysis of the operation, in the design and development of any object and of any material, in order to reproduce a new component that has a function similar to the first, or constructively improved, increasing in this case also its efficiency. This technique is often used when the obsolete component is damaged and / or worn even up to 80%, or when it is no longer possible to find the original spare part on the market or if very long procurement times are expected.
Predictive Maintenance - Thermographic Analysis
For a municipal company that manages drinking water, Predictive Maintenance with Vibration Analysis (CSI 2140) and Thermographic Analysis (Flir E6) have been performed. From the analyzes carried out it was possible to run a maintenance program according to the detected criticality. Predictive Maintenance and Scheduled Maintenance have allowed the customer to optimize maintenance and spare parts costs, minimize breakdowns, maximize process yield, and always have efficient items.
Supply of original and non OEM spare parts
Service Pumps Solutions is able to supply original spare parts and not OEM. Generally non-OEM replacement parts are required when a component is no longer available on the market or when through the Reverse Engineering and rapid prototyping is possible to replicate a complex geometric piece with very short delivery times.
Maintenance to failure - partial revision programmed on site
For a cogeneration plant using renewable energy produced from natural wood biomass to produce electricity and heat, fault maintenance was performed by planning with the Customer a partial on-site revision of the water-based pumps boiler feed. The partial review included replacement of the mechanical seals and bearings with new original spare parts. After which the motor / pump axle alignment has been performed and consequently the start up. Finally, the project parameters were verified during the pumping operation in transients and at full load, and efficiency analysis was performed with the acquisition and analysis of vibrations. A detailed report of the activities and the certificate of vibration analysis was delivered to the Customer.
Predictive Maintenance with CSI 2140
For the most demanding customers where in their production environments require greater controls of the most critical asset, was scheduled a predictive maintenance with the collection and analysis of vibrations with the CSI 2140. Service Pumps Solutions tool with the CSI 2140 instrument can operate in environments FM, CSA Class 1 Division 2 group (a, B, C, D) and ATEX Zone 2 IECex, and perform data collection and analysis of vibration to a higher level. The results are excellent, with reports to the Customers the criticality for each plant, machine and system were highlighted. As a result customers for their plants were able to program all the activities to maintain or improve the conditions of efficiency, effectiveness, operational availability, operational reliability and process yield.
For a bottling plant, transfer and handling of liquefied petroleum gas, the maintenance to faults using the total revision activities of a horizontal multi-stage centrifugal pump was performed. The total revision activities included disassembly with cleanliness, dimensional / geometric control of which the pump components. technical / commercial offer issued. After the customer's order the pump was reassembled by replacing worn parts with new genuine parts. In the end of the compressed air leakage test was performed, and painting. Subsequently, the on-site activities with the installation of the pump is performed, align the motor / pump axis, verification of regular flanged couplings between the intake and discharge lines with corresponding flanges of the pump. In the end it was performed starting with the efficiency of verification and the operating parameters. Issuance of the final report.
Preventive Maintenance - Safety Valves
Cogeneration plant. E'was performed preventive maintenance on condition according to the regulations that provide for the control of the two-year safety valves with mechanical overhaul and calibration activities at the test bench in the presence of the officer of the certifying agent. We also report that we are able to operate on-site valves can not be removed by the installation with appropriate equipment for their review, calibration and functional testing with the implant in operation.
Predictive Maintenance
In a pumping station to use conveying water to a artificial basin, was performed with Predictive Maintenance riliefs and vibration analysis. The analyzes carried out on the motor / pump have detected problems caused by the misalignment of the axes of the machines, by the imbalance static / dynamic of the rotating masses, from electromechanical problems, bases of carpentry entering into resonance with the motor / pump. In the report given to the customer, have been supplied the vibration analysis to show data not admissible and the causes of the problems associated, proposing for each Item as a function of criticality of the plant, the corrective actions to be carried out as corrective maintenance, preventive to be performed programming.
Predictive maintenance and effciency analysis
Activities predictive maintenance and verification of efficiency performed in the groups of pumping vertical axis in a pumping station river water for irrigation. They were used the main predictive techniques: thermography and vibration analysis. Thermographic analysis has highlighted a problem to a phase of a motor. From the analysis of vibration it is noticed a turbulence in the pump suction caused by the phenomenon of cavitation. To complete the analysis have been checked all the operating parameters of pump groups. From the analysis it was possible to take corrective actions to be programmed in preventive maintenance.
Overall revision gear pump
Maintenance to failure with total revision of a gear pump and realization new spare parts with the aid of the technique of Reverse Engineering. Procedure maintenance work, first analysis: verification of the status of all components of the pump, control dimensional/geomatric parts, non-distructive testing. Failure analysis: The failure of the ball bearing has caused breakage of the shaft command in drop zones, the top cover and of the pairs of conical gears suitable for the trasmission of motion. Recovery actions: Using the technique of reverse engineering were performed in rapid prototyping models in 3D, the two-domesional construction drawings of all the components and as a result have reproduced and built new parts also improving the quality of materials. Mounting the pump: check all components of the gear pump, check all the games assembly, pump mounting, test the free movement of the rotors, leak test.
Breakdown maintenance and corrective maintenance
Activities replacement bearings - three-phase motor; P = 132 kW; n = 2955 r / min. Analysis of the problem of the bearing: Overload concentrate for a strong misalignment of the axes of the machine; Static and dynamic imbalances that have determined high values of vibration of the rotor both radially and axially; Excess amount of grease placed on several occasions in the bearings which caused a strong overheating of the whole system bearing / seals fat. Service Activities: Alignment analog axis motor / pump; Proof of operation of the unit during the transitional phase and the point of operation; Detection and analysis of the vibrations in the transition phase and the point of operation; Writing the final report on the problems encountered and the causes that led to the problem; Corrective actions and recommendations for proper handling of machinery and plant.