Project Name: Water Pump Installation
Completion Date: Pump A – 04/11/2022, Pump B – 17/03/2023
Location: United Kingdom
Type of Project: Installation on existing foundation
Industry: Oil & Gas
Project Overview
The Water Pump Foundation Installation was a successful undertaking, executed by Alphatec Engineering. The project involved the replacement of two outdated pumps from the 1970s with modern, more efficient pumps supplied by Flowserve.
The installation took place in two phases, with Pump A installed in November 2022 and Pump B in March 2023. The primary goal was to enhance the refinery’s water processing capabilities and improve overall operational efficiency.
Unexpected Difficulties Encountered
Throughout the installation process, Alphatec Engineering faced several unforeseen challenges. The initial difficulty arose when it was discovered that the pump supplier had painted the entire skid, neglecting to clean the underside as required by API RP 686 standards.
image source: api.org
Furthermore, the corners of the skid had not been rounded off to a 1″ radius, potentially creating stress points. Additionally, adverse weather conditions in November posed difficulties for the installation team.
Overcoming the Difficulties
To address the challenges encountered during the installation, Alphatec Engineering took proactive measures. They removed the paint from the underside of the skid using an angle grinder and flappy disc, ensuring compliance with API RP 686 requirements.
The corners were also rounded off to mitigate potential stress points, enhancing the structural integrity of the installation.
To cope with the bad weather conditions in November, the team implemented additional scaffolding and sheeting to protect against rain and maintain the project’s progress.
Lessons Learned
The Water Pump Foundation Installation project provided valuable insights for both the client and the pump supplier. The lessons learned from the initial installation helped improve the second phase.
In Pump B’s installation, the pump skid’s underside was left unpainted, and the corners were properly rounded off from the outset, demonstrating the benefits of applying past experiences to enhance future projects.
Successes and Achievements
The project was completed successfully and on schedule, with both pumps installed according to plan. The client expressed great satisfaction with the results.
This project was their first experience using Alphatec 800, an epoxy grout, which they found to be more economical and easier to use due to its lack of temperature restrictions and the non-requirement of heating for curing.
AT 800 in situ
The successful installation of the new pumps led to improved water processing capabilities and enhanced operational efficiency at the Refinery.
Environmental Impact
The Water Pump foundation Installation not only marked a significant advancement for the Refinery in terms of operational efficiency but also demonstrated a commitment to environmental sustainability. One of the key aspects contributing to the positive environmental impact of this project was the strategic use of epoxy grout for the pump installation.
Compared to traditional cement grout, which often requires multiple regrouting over time, epoxy grout offers a superior and long-lasting solution. By utilising epoxy grout for this installation, Alphatec Engineering ensured a “first-time right” approach, significantly reducing the need for future maintenance interventions. This reduction in regrouting not only saves resources but also minimises the production of waste materials associated with repair and maintenance activities.
Moreover, epoxy grout’s superior durability and resistance to chemical corrosion make it an ideal choice for harsh industrial environments like the oil and gas industry. The prolonged lifespan of the epoxy grout used in the pump installation contributes to a lower carbon footprint by decreasing the frequency of replacement and the associated manufacturing and transportation impacts.
Additionally, the proper alignment and levelling achieved through the use of epoxy grout enhance the pump’s efficiency, leading to reduced energy consumption during operation. This energy efficiency translates to lower greenhouse gas emissions, aligning with broader efforts to combat climate change.
Conclusion
Alphatec Engineering’s successful execution of the Water Pump Foundation Installation showcases their expertise in handling intricate projects within the oil and gas industry.
By efficiently addressing unexpected challenges and implementing proactive measures, the team demonstrated their adaptability and commitment to delivering high-quality results.
The project’s positive environmental impact, achieved through the use of epoxy grout, further underscores Alphatec Engineering’s dedication to sustainability and responsible engineering practices.
As the installation served as a learning opportunity for both the client and the pump supplier, Alphatec Engineering continues to set new standards for future projects in terms of efficiency, reliability, and customer satisfaction. For more white papers and case studies, check out our success cases.
