Services - Service Pumps Solutions

The expertise, efficiency and reliability provided to Clients through our services makes Service Pumps Solutions a leading partner in the maintenance of pumps, valves and auxiliary systems. The aim is to accompany the Client in solving problems that can arise during the life of the machine - suggesting preventative maintenance, improvements and innovation. The implementation of innovative technological solutions is designed to maximize longevity and efficiency - ensuring optimum levels of service, operational safety and sustainability.

Often, strategically, the machine is brought to the point of failure. Or an unexpected fault occurs when the machine or plant is stopped. In the first case the failure is consciously expected while in the second case, major production problems can occur.

Service Pumps Solutions is ready to intervene at any time to resolve faults with pumps, valves and auxiliary systems. The initial inspection and fault analysis will be carried out; subsequently, once the corrective action has been defined together with the Client, the repair will be performed. Generally, the repair can be made on site where the machine resides. Alternatively, the work may be carried out at the Service Pumps Solutions workshop. On completion of work, a detailed technical report will be drafted on the entire procedure that was carried out.

Repair procedure:

General information / condition - recording of pump data plate
Historical maintenance information or predictive analysis
Disassembly, sandblasting, cleaning, visual / dimensional / geometric check of components
List of spare parts and component refurbishment procedure
Static balancing of components and dynamics of the rotor (if required)
Full assembly
Check the free movement of the rotor
Axis alignment of drive and pump
Start-up and efficiency check
Final report

Advantages for the Client:

Know who to call at any time to resolve emergency issues.
Entrust the machine to a professional partner.
Resolve an emergency situation, machine or plant downtime.
Contain losses (in costs) caused by the failure.
Return to a situation of efficiency and operational safety of the machine and / or system.

A component is designed to perform a certain job, but often the operating environment and requirements change over time as a result of configuration and system changes, production, maintenance issues, corrosion and extraordinary wear. As a result, the item may no longer be suitable for carrying out its work in the intended manner, reaching failure prematurely.

Service Pumps Solutions offers a re-engineering service aimed at improving components, pumps and systems. The service offers a complete analysis of the fault and reports on the recommended technological updates, operational, maintenance or process changes.

Advantages for the Client:

Life-extension of the component, pump, valve and related systems
Resolving safety issues and reducing the risk of future failures
Energy saving
Compliance with current environmental laws
Improvement of Maintainability
Availability of spare parts at any time (with the construction drawing available)
Improvements in reliability, efficiency, effectiveness and operational availability
Elimination of obsolete spare parts from the warehouse and associated reduction of cost
Control of degradation
Protection afforded by new component warranty
Process sustainability

In general, for pump service and overhaul, a failure and critical analysis is first carried out to enable the definition of preventive maintenance procedures. The timing of these procedures will be programmed as close as possible to when they deemed to be necessary. According to client needs, Service Pumps Solutions offers scheduled pump maintenance services:

Cyclical predictive maintenance is carried out according to established time intervals, or on the basis of a defined number of machines used without previous assessment of operating conditions.
Preventive maintenance, according to condition, includes the analysis and monitoring of operating conditions, test and inspection with the aim of assigning specific maintenance to the component, system and / or machine.
Predictive preventive maintenance is performed according to the forecast of the analysis of the reference parameters of the machines, or by evaluating their state of deterioration.

Partial pump overhaul: is carried out on site, and consists of a partial overhaul of the pump; the parts generally involved include the bearing support components, mechanical seals or stuffing boxes with braided sealing rings.
Partial overhaul activity:

General information / condition - recording of pump data plate
Historical maintenance information or predictive analysis
Disassembly, cleaning, visual / dimensional control of the parts
Standard spare parts
Assembly of all components
Check the free movement of the rotor
Drive / pump axis alignment
Start-up and efficiency check
Final report

Complete pump overhaul carried out at the Service Pumps Solutions workshop consists of the total overhaul of the pump where all components are concerned.
Complete overhaul activity:

General information / condition - recording of pump data plate
Historical maintenance information or predictive analysis
Disassembly, cleaning, visual / dimensional / geometric control of the parts
List of spare parts and component restoration activities
Static balancing (if necessary on new parts)
Dynamic balancing of the rotor
Assembly of all components
Check the free movement of the rotor, pressure test
Application of paint finish
Final Report

Advantages for the Client:

Maintain or improve the conditions of efficiency, efficacy, operational availability, and process yield
Reduce small stops, breakdowns, defects, start-ups, machine stoppages, efficiency loss, accidents and waste
Degradation and wear control
Gain operational flexibility by assessing the risks
Extend the residual life of the component, machine, system, plant
Raise operator professionalism (in awareness, peace of mind, motivation to exercise)

Among the primary maintenance services, Service Pumps Solutions also offers the repair or overhaul of valves of any type and construction. In many cases, the service is able to facilitate the complete restoration of efficiency and functionality of valves, even those which are very obsolete, heavily damaged or worn, and the verification of safety valves to comply with legal obligations that require, with specific intervals, efficiency and calibration control on the part of a Certifying Body.

PSV safety valve activity:

Bench, on site or in operation calibration
Issue of the certificate of a Certifying Body

Standard Activities:

Disassembly of all valve components
Sandblasting and cleaning
Dimensional/geometric component checks
Mechanical restoration processes (turning, lapping)
Supply of original and non-OEM spare parts including through Reverse Engineering
Valve assembly, pressure check using water or nitrogen
Bench calibration of valve
Application of paint finish according to specifications
Final report

Additional services:

Stellite hard facing (a wear resistant alloy), substitution with Stainless steel or Inconel (corrosion resistant alloys), etc.
Thermal treatments
Application of various coatings, depending on use

Advantages for the Client:

Maintain or improve conditions of efficiency, efficacy, operational availability and process yield
Reduce small stoppages, breakdowns, defects, start-ups, efficiency losses, accidents and waste
Degradation and wear control
Extend the residual life of the component, valve, system, plant
Verification and certification required by law

Service Pumps Solutions can provide static and dynamic balancing services on single parts and on complete rotors. Every rotating machine has a rotating element, the dynamic part subject to imbalance. Generally, a rotor consists of a shaft and the components keyed to it such as impellers, washers, bushings, discs, etc. Imbalance is understood to be the non-homogeneous distribution of mass with respect to the rotational axis. Due to the centrifugal forces of rotation, vibration and noise can be generated, amplified by any increase in the number of revolutions. In order for the pump, during service at different rotational speeds (transient or at maximum load), to present vibration within acceptable parameters, it is necessary for the rotor is balanced in advance; this process is aimed at improving the distribution of mass of the rotating bodies with respect to the axis. In each rotor there will always be a residual, but acceptable imbalance within the reference standard parameters.

Imbalance can be classified into static, coupled and dynamic. In practice, only two types are considered: static and dynamic. The appearance, function of the rotor and the type of balancing affect the position of the correction planes and the choice of the balancing tolerance.

Static imbalance:

Static imbalance produces an effect under quiet conditions. Essentially, it occurs when the rotor's center of gravity is not coincident with the rotational axis. Positioned on two supports, the rotor oscillates on its own axis, moving the point of greatest mass to the lowest position due to the effect of gravity. For static balancing, generally vertical balancing machines are used and the correction is carried out on a plane.

Dynamic imbalance:

Dynamic imbalance occurs when the rotor set in rotation produces an effect. In this case the imbalances are infinitesimal, distributed along the entire rotational axis. In practice, this distribution can be grouped into two resulting imbalances which generally have different angular values and positions. To dynamically balance, horizontal balancing is used and the correction is performed on two selected planes.

For the detection in the field of dynamic rotor balancing with machines in service, Service Pumps Solutions can offer non-destructive methods employing the following techniques:

Vibration and waveform analysis
Vibration phase analysis
Visual inspection of components visible from the outside such as: transmission joint, balance fifth wheels, etc. (with stationary machines)

Advantages for the Client:

Minimize the vibrations induced by the machines to within acceptable parameters
Increased machine efficiency
Achievement of expected component life
Reduction or elimination of failure caused by imbalance
Operational safety

Condition monitoring is the process whereby the specific parameters of one or more machines are acquired and analyzed; facilitating advance recognition of an anomaly before it effectively becomes a fault. Anything that can be measured, acquired and transformed into mathematical language can be analyzed, controlled and improved. The most common monitoring parameters include: vibration, temperature, pressure, flow rate, voltage, current intensity, etc. Through condition monitoring techniques, with historical data and trends, Service Pumps Solutions uses predictive maintenance to determine the status of the machines and plan, together with the Client, planned maintenance and the supply of spare parts. The Condition Monitoring service offered by Service Pumps Solutions uses non-destructive techniques that are most frequently used on pumps, turbines, compressors, motors, partly completed machines, rotating and reciprocating machines in general.

Monitoring with portable analysis equipment
Monitoring with portable analysis equipment is performed by a technician who carries out measurements on specific points taken in succession (route-based) at predetermined intervals. The analysis can be carried out in real time, or later by transferring the acquired data to dedicated software. Depending on the criticality of the machines to be monitored, Service Pumps Solutions will suggest specific data acquisition rates (route-based). The Customer has the option of requesting a timely predictive analysis or, in anticipation of repeated deadlines, Service Pumps Solutions offers dedicated contract services.
Monitoring techniques offered by Service Pumps Solutions with portable analyzers:

VIBRATION ANALYSIS
THERMOGRAPHIC INSPECTION
LUBRICANT ANALYSIS (tribological analysis)
ULTRASOUND ANALYSIS (detection and analysis of compressed air leaks)

Monitoring with fixed instruments (Industry 4.0)
Generally, monitoring with fixed instruments is performed solely on critical machines within equally critical processes. In this case, monitoring is performed continuously and alarm thresholds are triggered when a parameter drifts towards the critical threshold. This monitoring system with fixed instrumentation integrates perfectly with more structured logics and Industry 4.0 systems.
Monitoring using fixed contact instruments can be carried out in two ways:

Wired monitoring with fixed contact instruments.
The sensors are mounted directly on the machine and the sensor leads connected to the analysis system.
Wireless monitoring with fixed contact instruments using a transmitter and remote receiver.
The sensors are installed directly on the machine and, via a connected transmitter, sensor data is sent to a remote receiver over a wireless connection.

Advantages for the Client:

Know the status of the machines
Coping with conditions that reduce longevity before they turn into a breakdown, simultaneously avoiding the consequences
Plan a maintenance schedule or other activities well in advance
Elimination of sudden machine downtime and plant downtime
Maintaining the efficiency of the machine in operational safety
High level of plant safety
Minimize maintenance costs
Increase plant availability
Concrete benefits - innovative investments - Industry 4.0 advantages

Today, with the support of Industry 4.0 and by virtue of new and increasingly sensitive digital technologies, probable anomalies can be predicted well in advance. Subsequent Scheduled Maintenance aims to improve the productivity, efficiency, reliability, competitiveness and sustainability of assets. Service Pumps Solutions can provide fixed instrumentation for data acquisition and software for checking alarm thresholds and first analysis – viewable on laptops, tablets or smartphones. Data transmission can take place remotely via cable. Fixed instrumentation is generally used for critical assets and environments.

The motion is transferred from drive motor to operating component via a coupling with a transmission joint. In order for the machines to operate optimally, within permissible vibration parameters, the alignment of the axes must be guaranteed by a correct coupling of the transmission joint, performed using appropriate measurements with specific instruments.

Misalignment of the axes can originate from several points, including incorrect assembly of a joint, poor fastening, an operational displacement of the axis or due to thermal expansion.

The consequences of misalignment include:

Increase in vibration amplitude
Reduction of component life (bearings, joints, lubricants, etc.)
Increased risk of breakage
Risk to operators
Economic losses due to production downtime and emergency maintenance

According to the operating conditions of the machines and the type of transmission joint, Service Pumps Solutions adopts the following axis alignment techniques:

Straight edge and feeler gauge - accuracy ≥ 0.1 mm
Dial gauge - accuracy ≥ 0.01 mm
Laser - accuracy ≥ 0.001 mm

Before each alignment, the soft foot condition is checked and, if present, corrected. In addition, for detection in the field of axis alignment with machines in service, Service Pumps Solutions can offer non-destructive methods using the following techniques:

Vibration and waveform analysis
Vibration phase analysis
Infrared thermography
Strobe lamp
Visual inspection

Service Pumps Solutions offers, among its main services, Reverse Engineering. It consists of the swift analysis of an object of any shape and material, in order to reproduce a new component of similar functionality or technological improvement – in this case also increasing its efficiency. This technique is often used when the obsolete component exhibits damage or wear, even up to 80%, or when it is no longer possible to find the original spare part on the market or due to very long lead-in times.

The Reverse Engineering techniques adopted for the production of non-OEM spare parts include:

Optical digitization systems
Analogue and digital measuring instruments
Chemical and structural analysis - FEM modeling finite element simulation
Project and drawing implementation

Technologies and supplies to support Reverse Engineering include:

‘Lost’ plug and mould production techniques
Semi-finished products by foundry casting or by forging
Semi-finished products for trade
NDT (non-destructive testing)
Thermal treatments
Products finished by mechanical processes incorporating interrupted or continuous machining – manual or CNC
Surface coatings
Static and dynamic balancing

In addition to the common methods of producing non-OEM spare parts, according to particular needs and following an accurate feasibility study of the component to be replicated, Service Pumps Solutions can supply components produced by the Additive Manufacturing technique. Additive Manufacturing is a technique that can be used to build very complex components and of different types of material from polymers to metals. The additive process starts with a digital 3D model converted into a usable format for processing. The base material is deposited, and then progressively built up layer by layer similar to a common printer.

Why use additive manufacturing?

Sometimes, the necessary component is not available when needed, or is out of production and therefore no longer available. In these cases, or to improve the design, additive manufacturing can also represent the opportunity to recreate the same component to offer greater efficiency and reliability. Components can be made using original construction drawings or a design obtained with the help of Reverse Engineering. Additive manufacturing is more convenient for small production runs and rapid prototyping, where the process helps to contain economic expenditure.

In particular, after being made, the item can undergo other treatments and processes if necessary, including: thermal or chemical treatments, finishing processes using machines for de-burring, turning and milling, etc.

Advantages for the Client:

Reproduce a geometrically complex replacement improved from the topological point of view
Short lead times for small quantities and complex shapes
Partial reconstruction of one or more components forming part of a single more complex unit

Verification of the integrity of an original spare part:
In the event that the original spare part has, for example, a manufacturing defect or damage due to transport, Service Pumps Solution will, upon its receipt, check its integrity, visual status, data label and any associated documentation.

Non OEM Parts:
Service Pumps Solutions performs checks on receipt of all standard and non-OEM spare parts available on the market, verifying their integrity and documentation. The highest quality is guaranteed on non-OEM spare parts directly built by Service Pumps Solutions, maintaining the same characteristics of the original spare part or even improving the technology when required or necessary. The component is followed throughout the manufacturing cycle, from the design phase, passing through the semi-finished product to the finished part. Accompanying the non-OEM spare part, all necessary documentation and certification of the material, non-destructive and destructive tests, heat treatments, coatings, etc. is issued to the customer.

How it is managed:

Stipulation of the deposit account contract: temporary, annual, multi-year, personalized
Insurance Policy
Creation of a Deposit Account Register
Preservation of assets according to specifications
Logistics management

Advantages for the Client:

Reduction / elimination of own warehouse costs
Certainty that the asset is preserved and maintained in efficiency according to specifications
Logistics management entrusted to the supplier
After verification and any maintenance planning, you are able to strategically choose the spare part to keep ready for use
Stock optimization

EFFECTIVE MAINTENANCE SERVICES MADE TO MEASURE

PUMP REPAIR FAULT MAINTENANCE

IMPROVED MAINTENANCE WHEN REPAIR IS NOT ENOUGH

PUMP OVERHAUL PREVENTIVE MAINTENANCE

VALVE OVERHAUL AND REPAIR

ROTOR REMANUFACTURE

STATIC AND DYNAMIC BALANCING

CONDITION MONITORING

The Industry 4.0 Advantage

AXIS ALIGNMENT

REVAMPING

RETROFITTING

REVERSE ENGINEERING

ADDITIVE MANUFACTURING

SUPPLY OF SPARE PARTS

DEPOSIT ACCOUNT

Head Office