Vertical Pump Motor Manifold Upgrade (VPMM)

Member Login | Contact Us

Vertical Pump Motor Manifold Upgrade (VPMM)

The current High Pressure Fluid System that controls your GE Large Steam Turbine has probably been in operation for 25 years. Even though it may have been functioning well during that time, it is likely beginning to show signs of aging.

DETERIORATING SIGNS:

SLOW RESPONSE DURING TRANSIENT OPERATION CAUSING THE STANDBY PUMP TO START
INCREASED OCCURRENCES OF HYDRAULIC LEAKS CAUSED BY PUMP VIBRATION
SHORTER AND MORE COSTLY MAINTENANCE CYCLES
INCREASED SERVO VALVE WEAR

IN ADDITION TO THESE PROBLEMS, the pumps, filter heads, relief valves, and check valves have
become obsolete which makes it difficult to find replacement parts.

SOLUTION:

Replacing the entire high pressure fluid system would be very expensive but replacing only the components that are causing problems or are obsolete is a cost effective solution to assuring a reliable system.

The existing design of the high pressure fluid system has the pumps mounted horizontally above the fluid level. This configuration has caused a number of problems with system operation and increased pump wear. Most pump manufacturers agree that the pumps should be located below the fluid level in order to operate more efficiently (flooded suction).

The VERTICAL PUMP · MOTOR · MANIFOLD UPGRADE positions the pumps in a vertical position below the fluid level. In addition, the new pumps utilize state-of-the-art technology which allows the pumps to respond to system flow changes much faster than the existing pumps. The existing pumps go from no flow to full flow in approximately 2 to 3 seconds. The pumps used on the VERTICAL PUMP · MOTOR · MANIFOLD UPGRADE go from no flow to full flow in less than 140 msec.

The Upgrade consists of two independent assemblies which include the following items:

Baldor 1800 rpm 440vac Motor
Oilgear Company pressure compensated piston pump
- The pump is connected to the motor in a vertical direction which positions the pump below the fluid level (flooded suction)
Ball type 2-1/2" inlet isolation valve
Special pump/motor/manifold mounting assembly which incorporates all of the following devices in one compact, easy-to-access location:
- Pump discharge relief valve
- Easy access, three micron, beta 200 pump discharge filter with built in differential pressure switch alarm (mechanical and electrical)
- Pump running pressure gauge with quick disconnect fitting
- Pump running pressure switch with quick disconnect fitting
- Pump discharge check valve
- Ball- type discharge isolation valve, which allows on-line service of all manifold components
Reservoir pad-type heaters replacing existing space heaters (Optional)
Heater control cabinet with dual-element RTD (Optional)
Real Time Fluid Condition Monitor (Optional)

THE UPGRADE consists of removing both inlet suction strainers, pumps, motors, relief valves, discharge filters, and check valves. Both existing space heaters are also removed in order to provide the space needed for the new vertical pumps.

After removing all of the pumping components, a rectangular hole is cut on the top surface of the Hydraulic Power Unit (HPU) on each side of the reservoir. This will be the location of the new pump/motor/manifold assemblies.

The new pump/motor/manifold assembly is then set into position and a 2-1/2" pump suction line with inlet isolation valve is connected to each pump.

On the upper portion of the pump/motor/manifold assembly, a new 1-1/2" drain line is fabricated between this manifold and the existing relief valve drain pipe on the HPU. A 1-1/2" main discharge line is also fabricated between each pump/motor/manifold assembly and the existing system distribution manifold.

Since the new motors are in the same physical location as the original motors and have the same horsepower rating, the existing motor leads can be easily connected to the new motors.

Optionally, new pad type heaters can be attached to the side walls of the HPU reservoir and wired up to a new heater control cabinet. The heater control cabinet provides provides a local set point and reservoir temperature indication.

An Optional Real Time Fluid Condition Monitor can also be added to the VPMM upgrade which continously monitors the water content and particulate levels of the pump discharge fluid.

Assembled Vertical Pump Motor Manifold Upgrade (Click to Enlarge)	Fabricated Discharge Piping (Click to Enlarge)
VPMM PAD Type Heaters (Click to Enlarge)	Heater Control Cabinet (Click to Enlarge)