The Re-Engineering Process
There are 6 steps in our Re-Engineering process, which are outlined in more detail below. Working in partnership with our Customers and taking their input ensures the optimized solution is offered.
We are happy to engage at any stage in a pump's life cycle, irrespective of the original manufacturer, whether for a FEED project, feasibility study or general consultation.
STEP 1 - CONSULTATION
We review the equipment details and project requirements together with the customer, determine the scope of the original purpose and application, review both the pump's original performance and current performance (these can be ascertained from the pump data sheets, test curves, general and sectional arrangement drawings, pump gauges and data logs) and required future performance outline potential solutions, and agree upon the way forward.
We then need to understand whether there are any existing operational problems being faced, to help define whether the problem is related to the pump or the system so we can tailor the optimum solution – be it upgraded materials, upgrading the pump, re-rating the pump, alternate materials of construction required etc.
Our Engineers can visit the site to review the pumps / systems in-situ, obtain any required information and even collect data about the components.
We can offer technical and commercial proposals based on nominal sizes of equipment and materials of construction, however to be able to supply components, we would need access to a sample components - either from stock, or preferably from the pump it will go into. This way we can ensure all mating parts are fit for the intended purpose.
STEP 2 - DATA CAPTURE
We employ laser scanning to obtain accurate, rapid and reliable data from sample components. Scanning can be performed at our service facilities or at the Customer’s site* to minimize downtime.
In addition to capturing data for the required parts, we will also capture the data of the mating parts, to ensure correct fits and clearances are applied.
Our laser scanning equipment is portable, meaning it can be moved to and around larger components to be scanned, such as pump casings.
The equipment has a laser mounted at the end of a CMM (Coordinate measuring machine arm) making a highly accurate 7-axis scanning device, capable of acquiring 750,000 points per second.
* With safety being top of mind for our employees and Customers, we need to ensure any equipment being worked on is suitably isolated and decontaminated, relative to the scope of work to be executed, and associated procedures completed e.g., POWRA, risk assessments, LOTO etc.
STEP 3 - MATERIALS ANALYSIS
Materials are analyzed to determine fitness for purpose**. Detailed photographs and condition reports identify any current issues (including original manufacturing flaws) or upgrade requirements, highlighting opportunities to improve the specific component or the equipment in general.
Using Positive Material Identification (PMI) devices, we can determine the chemical composition of the components. Testing for the hardness of the material can identify the form of supply.
Using this information, we can determine the suitability and compatibility of existing material, and make recommendations for any material improvements, being cognizant of any compatibility / galvanic corrosion issues that changing or mixing materials can bring.
** Any ‘fitness for purpose’ shall be as standard in the industry unless a variation from the normal use is specifically disclosed and agreed by the parties in writing.
STEP 4 - ENGINEERING, ANALYSIS & SPECIFICATION
All acquired data is reviewed alongside operational history to finalize our recommendations. The material specifications and stringent quality requirements are defined and detailed in the Quality Plans used in the manufacture of the components.
If there is a requirement to design out any cavitation issue, modify performance etc., then we can use Computational Fluid Dynamics (CFD) to benchmark and validate designs.
For pressure containing parts, especially where sample parts were old, worn and towards the end of their design life, we can use Finite Element Analysis (FEA) to validate wall thickness and integrity.
Materials of construction are fully specified by standard, grade and supplementary requirements.
All core components have Quality Plans which detail the steps in the manufacturing process including traceability, machining sequence, heat treat / stress relieve, chemical and mechanical tests, NDE and acceptance criteria.
STEP 5 - 3D MODEL & DRAWINGS
All the re-engineering inputs are brought together and the finalized design is generated
From the engineer’s scanned data we create a full manufacturing model and drawing of the part. These 3D models are used directly in manufacturing to ensure components are exactly as per our design.
The cast part is made directly from the 3D model – this has many advantages:
- CAD/CAM can be used, so there is no human interpretation of a 2D hydraulic drawing.
- A CNC machine can be used in the manufacture of patterns
- Additive manufacturing can be used for cores and patterns
The final machining drawing with dimensional and geometric tolerances is then applied.
STEP 6 - MANUFACTURE AND QUALITY ASPECTS
Engineered replacement parts are manufactured in accordance with our Original Equipment parts and ISO 9001 Quality Assurance system.
The manufactured parts are inspected against the Quality Plans throughout the process to ensure compliance, including material analysis, dimensional inspection, laser scanning to validate complex surfaces, material certification, test and balancing.
Pressure containing parts are hydrotested and rotating components are balanced to the required grade as specified in the Quality plans.
As well as traditional techniques for dimensional inspection, we use the laser scanner to verify profiles of hydraulic surfaces and validate geometric tolerances, by comparing it against the 3D model for manufacture.
This also allows the ability to compare the manufactured part scan data with the original part scan.
