Tag Archives: oil

Full Refurbishment for Island Refinery

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The process of reopening the plant had uncovered more than 500 pumps that needed considerable refurbishment and repair. The most important of these was a critical jet pump used for hydraulic decoking. It was badly damaged and sent to the original equipment manufacturer (OEM) for inspection. The OEM recommended that the refinery replace most of the pump parts, as well as a costly repair that would require 35 weeks to rebuild.

Viable alternative

Instead, the refinery sent the pump to global aftermarket pump service provider, Hydro, Inc. in Chicago, where it was refurbished for just over half the cost of the OEM proposal. The time involved was also significantly improved to just eight weeks by using a non-destructive evaluation and rebuild process at a 46,000 ft2 facility where Hydro develops and implements engineering modifications for improving the performance of critical pumps and then verifies that performance in their Hydraulic Institute certified test lab.

Significant reopening

The original refinery opened in the mid-1960s. In the early 1970s, it was re-rated at 650,000 barrels per day. It had been one of the largest refineries in the western hemisphere, so the impact of reopening the plant would be significant. In this case, Hydro was tasked to work with the critical highenergy pump to prepare for its reopening. The new owners began the process two years ago and it is expected that the plant will be open for operation in the first quarter of 2020. Once restarted, the plant will be able to process up to 210,000 barrels per day of oil, a fraction of the 1,500- acre (607-hectare) plant’s peak capacity in the 1970s of 650,000 bpd.

When the plant was shut down, the pumps and other equipment in the refinery were either left in place or went into storage where they were kept in poor condition. Time constraints prohibited proper preventative maintenance before the refinery shut down. The tropical climate is hot, salty, humid, oppressive, and several hurricanes occurred during this time. All of these extreme conditions can contribute to the deterioration of heavy rotating equipment. Over the course of the year, the temperature typically varies from 72°F to 88°F and is rarely below 68°F or above 90°F. Continue reading →

Landmark contract signed between Oman’s PDO and Hydro Inc.

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Hydro Middle East has a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs.

Hydro Middle East Inc. will provide aftermarket support for maintenance, rebuilds, retrofits, upgrades, re-rates, provide engineering support, conduct field service, and manufacture spare parts for PDO‘s entire centrifugal pump portfolio. Hydro Middle East has a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs.

Last year, Hydro Middle East and its agent Global Pavilion LLC were awarded a major 10 year contract by Petroleum Development Oman (PDO), the leading exploration and production company in Oman which is majority owned by the Government of Oman with Royal Dutch Shell, Total and Partex being the minority shareholders.

Hydro Middle East, the Dubai branch of Hydro Inc. group of companies having worldwide operations and headquartered in Chicago USA, has entered into a contract with PDO. With this contract, Hydro Middle East and its local partner Global Pavilion LLC will be responsible for a complete range of pump aftermarket services for both PDO’s high and low energy centrifugal pumps. In addition to the vital expertise that Hydro Middle East will provide to PDO, this contract also serves and supports the government’s initiatives to train young Omani engineers and utilize local resources within PDO local facilities.

Thomas Arakal, managing director of Hydro Middle East, noted that prior to Hydro’s arrival in the region, a need for high-level niche aftermarket engineering was not being served to industry here. “Hydro’s considerable engineering capabilities, along with ready and affordable access to our pool of experienced aftermarket engineers from our worldwide locations allow us to offer quick turnaround.”

George Harris, CEO of Hydro Inc. added, “With this new contract, Hydro looks forward to serving PDO’s needs while making an impact on young engineers in the region and helping to spread cutting-edge pump-engineering technology to this crucial region of the world.”

Hydro Middle East was established in Dubai’s National Industries Park with a state-of-the-art manufacturing and service facility for comprehensive pump maintenance and rebuilding needs. They are also licensed by American Petroleum Institute for drilling services (manufacture, service, testing, inspection of well control, pressure control and rig and drilling equipment, onshore and offshore).

Hydro has carved out a niche as the premier engineering and solutions based company for the oil and gas, power utility, nuclear, desalination, mining and petrochemical industries in the region.

Source: oilreviewmiddleeast.com

Close Inspection Solves High Thrust Bearing Temperature Problem

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Careful analysis identified the issue with this multistage, oil transfer pump.

Written by: Gary Dyson (Hydro, Inc.)
Publisher: Pumps & Systems / August 2014

 

A multistage BB5 diffuser machine in oil transfer service in the Middle East had been in operation for many years without problems. After a routine maintenance strip down and rebuild, the pump experienced a high thrust bearing temperature of 105 C, which caused it to alarm and shut down. The temperature range had previously been 75 C to 85 C.

This case study describes the method used to solve the high bearing temperature problem and outlines the flow physics that contributed to the high thrust bearing temperature. The customer contacted an engineering services company after the original pump manufacturer failed to remedy the problem.

The company’s forensic approach to this problem involved two distinct methodologies:

  • Diligent and in-depth analysis of site data relating to 
the problem
  • Rigorous scrutiny and analysis of the pump geometry and build against the background

The engineering services company identified several scenarios that could cause this temperature rise, then narrowed down the list to establish a root cause.

Site Data Analysis

The behavior of thrust bearing pads during startup is seldom investigated. The temperature rise of the pads can be attributed to two distinct causes—thrust developed during startup and environmental and oil conditions (see Figure 1).

thrust-bearing-pad-behavior

Figure 1. Behavior of thrust bearing pads based on thrust and environmental conditions (Article images and graphics courtesy of Hydro Inc.)

The significant finding from this data was the temperature rise associated with thrust. The pump could not achieve the temperatures measured prior to maintenance in its current condition. The total thrust bearing temperature includes the oil temperature and environmental conditions.

Based on comparisons with previous site data, both the thrust and oil cooling had altered. Analysis of the temperature data at the motor bearings, which were experiencing oil temperature increases of 10 to 15 C, further supported the conclusion. Continue reading →