Challenge: Accelerated Pump Wear and Efficiency Loss
A power generation client in Western Canada experienced efficiency loss in their ash sluice pumps due to severe erosion of pump base materials. This issue was intensified by changes in the pumped fluid composition, which introduced a new stream of dirty fluid, accelerating wear. The pumps, an older design no longer supported by the OEM, required extensive repairs to restore performance. The client faced challenges including:
- Material Corrosion: Pump casing, wear parts, and impellers exhibited major corrosion damage.
- Complex Repairs: Specialty welding was required to restore the integrity of the cast iron casings.
- Limited OEM Support: The original manufacturer could no longer provide replacement parts or repair services.
- Tight Deadlines: Replacement impellers needed to be sourced and delivered quickly to minimize downtime.
Westpower’s Solution: Engineered Repairs and Upgraded Components
To restore pump performance and extend service life, Westpower implemented an engineered repair solution, leveraging 3D scanning technology and precision engineering:
- Reverse Engineering & Part Manufacturing: Replacement impellers were supplied in upgraded materials to improve durability and extend mean time between failures (MTBF).
- Specialty Welding & Machining: Extensive welding and machining processes were used in restoring pump casings to re-establish clearances, fits, and flow paths to OEM specifications.
- Protective Coatings: Epoxy coatings were applied to mitigate future erosion.
- Inventory Optimization: The client now has a reliable source for spare parts, with common spares shared between sites to improve availability and reduce repair lead times.
Outcome: Increased Efficiency, Reduced Downtime, and Long-Term Reliability
By partnering with Westpower, the client successfully restored pump efficiency and improved overall reliability:
- Pump Performance Restored: The rebuilt pumps now operate at their original design parameters, allowing the client to meet process demands while running fewer pumps.
- Lower Maintenance Costs: Extended MTBF reduces the frequency of major repairs, leading to cost savings.
- Minimized Downtime: With pre-manufactured spare parts readily available, future repairs can be completed more efficiently.
- OEM Independence: When the OEM could no longer support repairs, Westpower provided a cost-effective, tailored solution that met the client’s operational and financial constraints.
This ongoing pump rebuild program ensures the client can maintain peak operational efficiency while significantly reducing maintenance challenges and costs.
