As pump demand grows, pump manufacturers are having problems keeping up with demand from existing pipeline companies that need more capacity or are adding new pipeline operations. The midstream pipeline business is booming, and pump manufacturers cannot keep up with the demand. Lead times are getting longer and longer.

To resolve this problem, many pipeline operators are turning to a new reality in the pump supplier business: remanufactured pumps. With the advent of sophisticated hydraulic engineering tools, a midstream operator can take existing pump inventory and capitalize on it by having pumps remanufactured to meet new specifications.

Similarly, many pump suppliers have an inventory of pre-owned pumps that can be remanufactured to meet an existing or new application. Whether the pump comes from a customer’s inventory or from the supplier’s inventory, the remanufacturing process is the same. The process addresses all aspects of the pump, including materials of construction, internal fits and running clearances and mechanical and hydraulic design.

One of the major benefits realized from using remanufactured pumps is the utilization of existing pump assets no longer required in original service. As sustainability and recycling become more dominant in corporate culture, reusing existing pump inventory can add to a company’s economic and environmental portfolio. With the ability to have a remanufactured pump available in 12 to 18 weeks, a midstream pipeline operator is no longer subject to the longer delivery schedule of a new pump manufacturer— which can take as long as a year.

Surplus to useful

Whether it is a 4 kilowatt (kW) (5 horsepower) single stage unit or a 2,250 kW (3,000 horsepower) high-speed, multistage unit, a remanufactured pump can help achieve a fast turnaround. The challenge in the remanufacturing process is to remanufacture a pump from a used or surplus piece of equipment to something that will meet or exceed the mechanical, hydraulic and service life requirements of the end user.

Many midstream pipeline companies have new pump expenditures budgeted into their purchasing plans. So while cost might not be a factor in the purchase of a new pump, the delivery schedule might be a hindrance.

Remanufactured pumps are also ideal to use if a pipeline needs more capacity or is changing over to other products. For example, if a midstream customer is looking to double the capacity of a pipeline, then pump flow needs to be doubled. A remanufactured pump can be supplied, tested and delivered in a shorter lead time. Most remanufacturing companies will accept a used pump as a trade-in toward a newly remanufactured pump.

To fully understand the benefits of a remanufactured pump, it is important to note the distinction between a remanufactured pump and a repaired pump. A remanufactured pump is not just a repaired, used piece of equipment with a new coat of paint. Within the remanufacturing process, repairs are commonly made to renew certain parts, but the overall process is very comprehensive and involves much more than just repairing or replacing parts.

The remanufacturing process starts with a surplus pump that is repurposed for new or existing service. Some pumps may require only minor upgrades while other pumps may require complete refurbishing of major components. In either case, the goal of the remanufacturing process is to return all pumps to like new condition.

The process

Each pump selected for remanufacturing goes through several steps before it is deemed ready for use. These steps include: disassembly, inspection of all parts including case/barrel, impeller, shaft, bearings and bearing housings and wear parts; engineering review including hydraulic design evaluation, pump construction and manufacturing routing assembly; and performance testing.

• Disassembly ?The disassembly procedure is a critical step in the remanufacturing process. During disassembly, important information is collected that will ensure the pump selected is correct for the intended service. Care must be taken to avoid damaging any components that may be used in the manufacture of the new pump. After initial inspection, the pump is dismantled for cleaning.

• Inspection ?During this process, critical dimensions are inspected for size, concentricity, and overall condition, and critical components are inspected. These components include the case/barrel, impeller, shaft, bearing housings, bearings and wear parts.

• Engineering ?Review When the inspection process is complete, the information gathered from the disassembly inspection procedure, along with the order specifications, is used to determine the pump remanufacturing requirements. This review outlines all aspects of the remanufacturing project including repair requirements, hydrostatic testing, rotating element balancing and performance testing, if required.

• Assembly ?The final step in the remanufacturing process is the assembly of the pump.

• Performance Testing ?To ensure pump performance to predicted and guaranteed levels, a mechanical run test or a full hydraulic and mechanical performance test may be specified. This may also include a net positive suction head test to verify performance.

In the remanufacturing process, the only part that is revitalized and reused is the original pump casing. All the other components inside the casing are restored or replaced to return the pump to like-new condition. If a part cannot be repaired or refurbished to like-new condition, then it is replaced.

Parts are also replaced if they cannot meet the remanufactured pump’s new specifications. For example, a pump might have a fully functioning impeller made of cast iron, but the new application calls for an impeller constructed of Grade 316 stainless steel. In this case, the impeller will be replaced. In effect, remanufactured pumps are custom-designed to meet the user’s specifications. A remanufactured pump supplier can customize the performance of an existing pump and re-rate it to extend the pump’s life and make it usable for another application.

Each remanufactured pump undergoes all the same meticulous manufacturing process details as a new pump, including full-performance inspection and testing.

A remanufactured pump also offers the same warranty as those available when buying a new piece of equipment. There is no risk of being forced to accept an inferior warranty when buying a remanufactured pump. The standard 12- to 18-month warranty comes with each remanufactured pump and assures the customer that it will meet or exceed the required specifications.

Any reliable remanufacturing pump supplier will offer software programs that take the stress out of searching for a remanufactured pump. As an example, Best PumpWorks has a selection tool, RePOD (Remanufactured Pump on Demand), specifically designed for remanufactured products. Its website can search its inventory of more than 3,000 pumps by type, brand or conditions of service and create a list of possible choices. RePOD searches can be constructed by conditions of service such as head, flow and process data and then by manufacturer and pump type. Especially useful are the pump curves available for the different models and sizes in inventory. All pump curves are digitized and key calculations standardized to save time and provide accurate data when searching for the appropriate pump to meet an application. It is essentially the same process that a customer would experience when buying a new pump.

Remanufactured pumps are reliable pieces of equipment that help the midstream pipeline customer complete projects faster and get product flowing sooner. They offer cost savings, increased profitability, shorter turnaround times the ability to use existing capital and the same warranties as a new pump purchase.

Comments