Even water bearers need an overhaul every now and then.
More complex than it first appears – a standard overhaul of a 20-year-old tubular casing pump. A glimpse into the day-to-day life of our colleagues at FLUIDSERV.
At an impressive 8 meters long, approx. 1.5 m across and weighing over 20 tons, this “water bearer” pumps approx. 8000 m3 per hour to a delivery head of 45 meters. That would fill almost 1000 bathtubs every minute. Since being commissioned in 1999, the job of the vertically installed tubular casing pump has been to convey cooled water from an upstream cooling tower back into the process circuit. A truly Sisyphean task for a robust tubular casing pump with interminable stamina.
Just removing it will take about a week. On site, the client will need to ensure that the pump sump has been sealed off, drained and cleaned. The electric motor will also need to be decoupled by qualified electricians. Subsequently, the motor will be removed through the roof of the pump station and lifted out using a heavy-duty crane. The roof of the pump station can be opened, which is generally the case by design. The motor alone weighs several tons. Next, the rest of the pump will be lifted out and everything will be transported to the FLUIDSERV workshop.
To ensure that the system can continue to operate, a replacement pump will then be installed on site to act as a stand-in while the original pump is being overhauled.
In the FLUIDSERV workshop, the entire pump will be dismantled and cleaned so that all components can be scrutinized and precisely measured. The findings will be recorded in a detailed report. The report will also advise which repair measures are recommended or vital to ensure that the pump can be reinstalled and can operate safely and reliably over the coming years. The findings will be discussed in detail with the client during a comprehensive meeting (at FLUIDSERV premises or via video conference). The extent of repairs will be mutually agreed upon, calculated, quoted and finally commissioned by the client. If any special replacement parts are required, this can delay delivery times. According to sales manager Thorsten Nilles, this means that it is not unusual for repairs to take 3-5 months. In this case, it took 4 months.
As soon as all the components have been repaired, they will be shipped back, the replacement pump removed, the overhauled pump installed, and the pump recommissioned in collaboration with the client. These tasks generally take 1-2 weeks. The pump will then usually run for 10 to 15 years until the next overhaul is scheduled. A huge task. But just another normal day at FLUIDSERV. Executed to the client’s full satisfaction.
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