Page 92 - Industrial Plant 2015

Fig. 2 - Stress analysis: pump casing Furthermore, in view of the project requirement, for the
Fig. 3 - Stress analysis: pump and baseplate pumps to withstand nozzle loads up to 4 times the API
610 standard values, pump casing and baseplate
design have been verified and validated through FEM
(Finite Elements Method) analysis for structural rigidity.
Modal analysis of the main baseplates was also
performed to prevent any resonant frequency issue at
operating speed. All these activities are normally done
internally by means of advanced engineering software
tools (figure 2 and figure 3).
As a matter of fact, while the design and the
manufacturing of these pumps did not represent a
particular problem to Weir Gabbioneta engineers, the
CUT (Complete Unit Test) of the main water injection
pumps in particular has stretched the limits of the
existing testing facilities due to the size and weight of
the skids on one side and to the required electric
power and heat dissipation capacity on the other
(figure 4).
Built in the 1990s as state-of-the-art fully automated
installation to fit - with a remarkable engineering work
- the existing facility, the current test room arrangement
has been showing in the recent years some limits
against the increased size, required power and overall
complexity of the manufactured products.
From the early 2000s it was already necessary – mainly
for space reasons - to open an auxiliary site in the
neighborhood of the main manufacturing plant
(Cinisello Balsamo) and more recently in 2012 a new
production facility was started in Myszkow (Poland).
This latter has become the COE and main manufacturing
unit for the Gabbioneta and Begemann API 610 pumps
type OH2, OH3, OH5, VS4 as well as “low energy”
VS1, whilst the Italian operations remain focused on
larger and more complex BB and high energy vertical
pumps.

installed on a common skid with a high voltage electric A new suitable location

motor and served by an air cooled type lube oil console The need for a more modern production plant in order

designed in accordance with API 614 standard, strictly to give adequate response to the increasing

meeting the applicable project specifications. requirements in terms of products size, lean

Mechanical seals are manufacturing process and

double pressurized type, Pump casing and baseplate design have - last but not least – HSE
also equipped with air been verified and validated through FEM
cooled buffer fluid systems. (Health Environment Safety)
Each water injection pump (Finite Elements Method) analysis for
skid, not including the lube structural rigidity. Modal analysis of the standards became more
oil console, is 10.14 m in main baseplates was also performed to
length, 5.4 m wide and 4.2 prevent any resonant frequency issue at and more evident to the
m high at the motor, with a
operating speed Weir Gabbioneta

management over the

recent years.

As a consequence, after

total weight of 42,830 kg. having considered different

As standard practice for this class of pumps an options the decision was eventually taken to build a

extensive calculation process including pump rotor new state-of-the-art production plant bringing under

lateral and torsional analysis was carried out from the the same roof the activities currently done in Sesto San

design stage. Giovanni and Cinisello Balsamo sites, upgrading at the

Industrial Plants - May 2015

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