A power plant had recurring problems with Ingersoll Rand boiler circulating and injection water pumps with repeated bearing failures after just a few months of operation. We found that the shaft and shaft sleeves were made of the wrong material and excessive thermal growth of those components was the root cause of the failures.
Bearing housings were line bored and machined to the correct sizes and clearances. New shafts and shaft sleeves were made with the correct material.
Carbon steel bearings were replaced with stationary metallized carbon bearings to give it a longer life.
The mechanical seal housings were machined to open up cooling water spaces to reduce the seal face temperature.
The six pumps that were overhauled and modified have been operating over 6 years without issue.
The customer has seen a large reduction in maintenance costs for these very important pumps.
A diesel fuel storage and distribution facility had high failure rates with ANSI end suction pumps. One pump failed after a few weeks run time and led to several thousand gallons of light oil leaking into the ground and surrounding waters.
We were called in as a 3rd party to dismantle the pump and identify the root cause of the failure. The bearings had spun loose in their housing due to improper fit, the impeller and casing wear rings were badly worn and the mechanical seal ceramic seat was broken into several pieces.
The pump was rebuilt by NEPV including line boring and sleeving the bearing housings, all wear rings replaced, dynamic balance of the rotating element, and upgrade of the mechanical seal with tungsten carbide to reinforced carbon seats. The pump was installed, laser aligned to the motor and has run for 8 years with no problem. Since then we have rebuilt over 20 pumps for the terminal.
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