February 2020

manufactured using state-of-the-art equipment, including 3-dimensional laser scanning technology to create the engineering models that were used with the latest casting techniques to produce the parts. This manufacturing method greatly reduces the lead time compared to traditional pattern making processes. It also simplifies the manufacture of future replacement parts. Talwar added: “By adapting design concepts from Sulzer pumps, our engineers have managed to improve the performance of the existing pump and complete all the design calculations to verify the existing barrel would be safe in operation. A final hydro test was conducted to test the barrel and pipework to confirm its integrity before it was installed.” As well as creating new parts, Sulzer also updated the design of the drive coupling, which was previously a gear coupling. In its place, Sulzer installed a membrane coupling, which offers stable performance, absorbs damping vibration and is easy to maintain. Bespoke replacements At the same time, Sulzer also discussed the repair or replacement of the remaining seven pumps. Considering the age of the original pumps and the improvements that could be delivered by modern replacements, it was decided the most cost-effective solution would be to replace them with custom-made models from Sulzer’s GSG range of boiler feed pumps. To make the installation of the new pumps as simple as possible, the suction and discharge connections, as well as the centre-line geometry, would be identical to the originals. This would enable the pumps to be installed on exactly the same footprint and connected to the existing pipework easily. In terms of performance, the new pumps offer a 5% increase in efficiency over the ‘as-new’ figures of the original pumps as well as a lower power requirement, both of which will deliver on-going cost savings. Sulzer made a number of recommendations with regard to the materials used in the construction of the new pumps to minimise erosion by specific factors associated with this application. The repair and replacement programme has brought the plant back to original specification but with improved efficiency. The work was required in order to achieve a 50-year extension on the plant’s license to supply LNG to the national grid. As such, improving the performance of the power generation plant was vital to this effort, so returning it to better than 95% output was a major step forward. 30 | Plant & Works Engineering www.pwemag.co.uk February 2020 Energy, the Environment & Water Focus on: Boilers, Burners & Controls Sulzer engineers have managed to improve the performance of the pumps and increase efficiency. Tel: 07966 099124 ac@danstoker.com • Steam boilers 150-15,880kg/hr • Hot water boilers 30-8,000kW/hr • Pressures from 7-17 bar • Oil, gas or dual fuel • Long or short term hire • Full commissioning service • 24/7 support SALES ● HIRE ● EXPORT +44 (0)1992 451629 www.kingsboilerhire.com The UK's largest provider of industrial Steam and Hot Water boiler plant. Fast, efficient Nationwide service for planned or emergency cover, R & D projects or extra capacity. BOILER HIRE SPECIALISTS