Fletcher Moorland Project Management Services
Do you have an installation or refurbishment project you need to plan or do?
Do you not have the resources to do it?
Do you wish to out-source it?
Fletcher Moorlands Project Management Services can help you. Here’s an example....
One of our customers had three pump installations that needed to be renovated due to repetitive failure. They needed someone to plan and manage the whole project for them within a restricted timescale. The original installations continually failed vibration tests, this was highlighted as deterioration of the original concrete plinths and mild steel bases. In addition, these pumps were in an Explosion Hazardous area as a hydrocarbon called hexane (which has a low flash point and is highly flammable) was in use as part of the processes there.
We have a dedicated “Reliability Specialist” at Fletcher Moorland for work such as this. Working in close cooperation with the customer he performed a site survey and discussed all the required safety precautions for the work to be carried out. Full risk assessments and work procedures were prepared and agreed with the customer in advance of any work commencing. From that, work schedules including those for subcontractors and timescales for the project were worked out and submitted. In this case there were three subcontractors and labour requirements from the customer too that had to be planned and co-ordinated. Special tools would also be required, specifically non-sparking tools (made from brass or copper) to allow for safe work in an environment where potentially explosive hexane could be present. Because of the restrictions a special ‘Ex’ area safe camera had to be used for site photographs, which is why they are all in monochrome.
Once all work methods and schedules were agreed, the first actions required were to remove the old motors and pumps leaving the existing piping in place to allow for the approximate location of the new plinths and pumps. The old concrete plinths and steel reinforced bases were then removed leaving a bare floor on which to build the new ones.
One subcontractor had to make new stainless steel bases to exacting tolerances and food quality standards that were specified by the customer. This work had to be scheduled so that it was ready when required, and inspected to see if the work was to the required specifications. The new concrete plinths were shuttered and poured to a calculated position and height.
After 12 hours the bases, pumps and motors could be placed on top of the plinths so the mountings for them could be marked out. Afterwards the motors and pumps were moved away again. When ready the mountings were drilled out (green concrete to make it easier for the brass drill and screw threaded rod anchors for the new motors and pumps were secured into the base using epoxy resin. When set, the motors and pumps were fitted onto the anchors with rubber washers between the anchor height adjusting nuts and the base. The correct depth for the grout was set by tightening or loosening the adjuster nuts. Once the level and clearances were checked then the grout to be poured in.
Once the concrete and grout was set and ready, the lockdown nuts were tightened to the correct torque so that the rubber washers were compressed and the base compressed against the grout. The motors and pumps could be fitted and laser aligned precisely. Correct alignment is crucial, it ensures a maximised life for the bearings and shafts, reduced noise and vibration and improved efficiency through reduced frictional losses too.
The next process was the re-connection to the existing pipe work suction and discharge flanges. The customer required there to be no more than 0.05 mm (2 thou) deflection of pump shaft when the pipe work was connected, thereby not compromising the alignment of the pump and motor. To accomplish this new spool pieces had to be made and welded. These new spool pieces had to be made in a safe area (as they were stainless steel and welding was required) then taken back for installation in the hazardous area to be checked for fit, ensuring the shaft deflection was within the specified 0.05mm limit. If the tolerance was exceeded they were taken back to the safe area to be reworked. This took 2 days to complete to the customers required standards but it was still completed within the agreed timescales.
Once final inspections using vibration analysis were completed both by our project manager and the customer the work could be signed off and the new pump installations brought back online on schedule.
If your require us to manage a project like this for you, give our Reliability Engineer, Mr Dave Daly a call. He will be happy to assess your needs and plan an initial investigatory site survey with you.
