FLOW & LEVEL CONTROL


Huw Rodway, Global Re-Engineering Manager at Celeros Flow Technology, explains the limitations of reverse engineering, and why re- engineering is a better approach to pump maintenance and lifecycle extension


duty or media all affect the efficiency of flow control equipment like pumps. Operating equipment outside its original design parameters accelerates and exacerbates wear, corrosion, cavitation and erosion, resulting in pumps that no longer perform as required and, ultimately, premature failure. Reverse engineering can generate like-for-


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like parts, but it does nothing to address potential underlying issues. Re-Engineering, a technique offered by Celeros Flow Technology, proposes a comprehensive solution by enhancing pump performance and extending service life. So what does it involve? Re-Engineering takes a holistic approach to


pump repair and maintenance. Using the existing part only as a template, Re- Engineering incorporates engineering input, mating part analysis, component design optimisation, modern materials and manufacturing techniques to develop an enhanced solution that can have an extended service life and lower total cost of ownership. In spare parts supply, Re-Engineering


ensures a reliable source of components for pumps that are no longer available or supported in the market. Re-engineered parts can be designed to ensure that replacement parts or sub-assemblies fit precisely with existing parts and can even be standardised to reduce inventory. Re-Engineering supports enhancements


and upgrades by providing recommendations for mechanical and material improvements. For example, modern materials can be incorporated into re- engineered parts to increase corrosion resistance, extend service life and improve mean time between failures (MTBF). Emission


8 SEPTEMBER 2025 | PROCESS & CONTROL


aintaining process and control systems is an ongoing challenge. Changes to operating conditions,


Below: Before (left) and after repair (right)


RE-ENGINEERING ENHANCES PERFORMANCE


leakage can be improved with upgrades from gland packing to mechanical seals and from component to cartridge seal assemblies. Hydraulic re-rates


are another engineered solution


supported by Re-Engineering. Equipment efficiency can be improved to reduce running costs and CO2 emissions. Material enhancements, particularly of wear parts, allow tighter running clearances, reducing recirculation losses. Hydraulic surfaces can have efficiency coatings applied, reducing friction losses. The pump performance can be aligned to system characteristics to establish the best efficiency point and optimise the reliability curve. Output can be reduced to suit system or


process changes. This may require the rotor to be de-staged and/or the impeller diameter reduced, or a variable frequency drive could be implemented. Similarly, the output can be increased. In either case, a detailed analysis of the impact on the motor and other drive train equipment would be undertaken. Re-Engineering is already adding value for


many of our customers. For example, a UK Oil & Gas Operator required a holistic solution for their (2.5 MW) 12-stage BB3 Sea Water Injection Pump, manufactured by another pump company, which had failed in service. The customer consultation defined that the


pump required a solution to increase MTBF and optimise pump performance. Celeros FT combined Re-Engineering with additional upgrades of critical features within the pump, including the mechanical seals and existing bearing housings. During strip inspection, several impellers


were found to be damaged beyond repair. Celeros FT used Re-Engineering techniques to reconstruct these hydraulic components. Damage to the rotating assembly had also impacted the stationary components. The large, heavy pump casings were repaired and machined back to design intent, re-inspected and hydrotested to the project duty requirements. 3D models of the pump casings were then


used as the basis for the mechanical layout. A thorough assessment was completed to ensure full mechanical integration between the mating components, especially when both existing and Re-Engineered parts were being used. Celeros FT Re-Engineered and upgraded the


shaft and completed a full rotordynamic assessment of the pump unit, including a lateral critical speed analysis in accordance with API 610 Latest Edition. This assessment, coupled with an in-house


performance test at full speed (4000rpm), head (>2000m) and power at Celeros FT's Test Facility in Glasgow gave confidence to the customer that the Re-Engineered and Upgraded Pump would perform as required. Re-Engineering offers a robust alternative to


reverse engineering by addressing root causes of failure, optimising performance, and extending the life of critical flow equipment. Celeros FT’s Re-Engineering program helps operators minimise downtime, reduce total cost of ownership, and avoid the expense of installing new equipment and systems.


Celeros FT www.celerosft.com


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