Challenge: Frequent Pump Failures and Unreliable Performance
A client in Western Canada faced significant operational challenges due to the short mean time between failures (MTBF) of their booster pumps, which averaged only four months. The harsh produced water being pumped caused severe erosion and corrosion, leading to unpredictable reliability and frequent maintenance demands. Additional design weaknesses, including insufficient impeller retention, incorrect hydraulics for field conditions, improper mechanical seals, and inadequate bearing brackets, further compromised pump performance.
Westpower’s Solution: Engineered Pump Repairs and Material Upgrades
To address these recurring failures, Westpower implemented a series of engineered upgrades:
- Material Enhancement: Replaced cast iron casing components with corrosion-resistant Duplex materials.
- Improved Impeller Retention: Redesigned for a more secure, service-appropriate fit.
- Hydraulic Optimization: Re-rated pump hydraulics to match actual field operating conditions.
- Mechanical Seal Upgrade: Installed seals designed specifically for the application’s demands.
- Structural Reinforcement: Upgraded bearing brackets to a more rigid 360-degree style for improved stability.
Outcome: Increased MTBF and Reduced Maintenance Costs
Through these targeted upgrades, the booster pumps’ MTBF has increased from just three months to an impressive three to four years, significantly improving equipment reliability and availability. The client now experiences fewer maintenance disruptions, reduced spare parts consumption, and lower overall operating costs, ensuring long-term efficiency and performance in this demanding service.
