Sulzer Pump Maintenance Manual

[Niobe Hennigan]

Wedeveloped, together with Sulzer, an online condition monitoring solution for rotating equipment. The Sulzer Sense wireless IoT condition monitoring system is built for real-life needs and conditions. It detects possible equipment failures early on and optimizes maintenance planning. Sulzer's core strengths are flow control and applicators. The company specializes in pumping solutions and services for rotating equipment, as well as separation, mixing and application technology.

Until recently, automation of measurements and their subsequent analysis have proven cost-prohibitive. For this reason, only the most critical applications have been monitored and less critical equipment are still measured manually today. This has several disadvantages, namely:

Driven by the usual suspects of the Industry 4.0 transformation, namely the advent of ubiquitous and cheaper sensor technology, coupled with advancement in telecoms and cloud computing, enormous opportunities arise to generate useful operational data from these assets in a cost-effective manner.

As digital sensors become cheaper and more equipment is connected to the Internet (Internet of Things, IoT), there is an ongoing potential to convert data from the devices into actionable business insights. This can be translated into optimized predictive maintenance and maximized uptime of the process in question.

Today, the technology involved is becoming more affordable. It is easy and cost-efficient to deploy for new equipment or to retrofit in existing installations. This is particularly attractive in the general industry, such as pulp and paper mills as well as the sugar, food, and fertilizer industries, where configured pumps have traditionally not been equipped with such options.

Because the product is highly innovative, the team learned much throughout the R&D process, the industrialization of the product, and the ongoing operational model. Key learnings were mainly on the management of the project, which required numerous skillsets from across the company, as well as coordination and communication across multiple vendors to allow for ongoing improvements to design.

Vital to the success of the IoT condition monitoring project was the stewardship from within the business to identify and leverage these different skills, while at the same time gaining insight from key customers with the features that add value for their business efforts.

Sulzer is developing and launching a series of digital solutions to support the core business model of selling new equipment, services and retrofits. The company uses digital tools to turn its products into smart devices, allowing customers to have valuable insights into the equipment data. As digital sensors are becoming cheaper and more equipment is connected to the Internet (Internet of Things, IoT), there is an enormous potential to convert data from the devices into actionable business insights. This can be translated into optimized predictive maintenance and maximized uptime of the process in question. Today, the technology involved is becoming more affordable. It is easy and cost-efficient to deploy for new equipment or to retrofit in existing installations. This is particularly attractive in general industry, such as pulp and paper mills as well as the sugar, food, and fertilizer industries, where configured pumps have traditionally not been equipped with such options.

Sulzer Sense has been running at test sites for a few months now. It helps the operators identify process problems by just measuring vibration and temperatures. By combining measurement data from Sulzer Sense with other existing data, the customers have been able to improve their processes.

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The Sulzer ABS Robusta 200 and 300 series submersible pumps are portable, compact and lightweight. They are designed for dewatering applications involving fresh water or wastewater containing solids up to 10mm in size.

These portable submersible pumps are compact, meaning they can fit in sumps as small as 300 x 300mm in size. The Robusta range is also excellent in installations with shallow water, it has a removable suction ring that allows the pumping of water down to 3mm in height (in manual mode only). Typical installations include; flooded basements, flooded cellars, containers, drainage pits, pedestrian underpasses, swimming pools and gullies.

Sulzer has launched its new CPE ANSI process pumps, which are specifically designed to exceed the strictest energy regulations for all industries as well as meet the requirements of ASME B73.1.

Sulzer says it has improved the reliability of the CPE pump and reduced the risk for unplanned shutdowns by optimising the shaft sealing with improved sealing chambers and balancing holes. The heavy-duty rigid bearing units ensure a long bearing life and leak-free construction. In addition, the company says that the high standardisation, easy installation and robust construction equate to lower maintenance and operating costs.

Sulzer specialises in pumping solutions and services for rotating equipment, as well as separation, mixing and application technology. The company undertakes intensive research and development in fluid dynamics, process-oriented products, and special materials as well as reliable service solutions.

Founded in 1834, Sulzer Ltd. is a Swiss industrial engineering and manufacturing firm headquartered in Winterthur, Switzerland. They are a global leader in fluid engineering and specialize in pumping, agitation, mixing, separation, and purification technologies. They have 180 world-class manufacturing facilities and service centers all over the world. As an innovative company in its field, they need a maintenance system that helps them meet their goals.

In addition, the manual process of handling paper work orders and managing dozens of technicians without the use of mobile technology caused unnecessary delays. It would sometimes be days after the creation of a work order before a repair even began.

They knew they needed to make a change and began looking for a computerized maintenance management system (CMMS) that would meet their needs. They wanted to find a CMMS that had all the functions they needed in one centralized location.

Within two weeks of implementing Limble, they had uploaded all assets and work orders. After two months with Limble, the rate of completion for work orders rose by 76%. Now 92% of their work orders are completed on time and there are numerous other actionable reports available for the first time ever.

Management finally has a grasp on downtime, labor costs, problem assets, replacement costs, spare parts spend, and so much more. Now that they are finally getting ahead, Sulzer has also been able to start the switch from failure maintenance to preventive maintenance.

Sykes Pumps has been synonymous with the pumping industry for more than 160 years. Our reputation for quality and service is unrivalled within the industry and backed up by a genuine commitment to reach customers within a 4-hour timeframe, regardless of their location.

As you would expect we also offer an unrivalled spares service from over 28 locations in the UK. We supply genuine manufactured Parts for all spares requirements on Sykes Pumps units along with genuine parts from other manufacturers whether that is for engines, electric motors or specific units supplied by Sykes Pumps. We offer genuine parts for the following:

We only ever offer original-quality parts, not cheaper imitations for quality and reliability

Parts always stocked ensuring no waiting times

Fast delivery to any location

All Sykes spares supplied straight from the manufacturer

We have over 28 local stocking locations across the UK

For information about our user manuals and list of parts, click here.

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