CASE STUDY
Industry: Power Generation
Conhagen’s West Coast Division recently completed a critical project for a Northern California energy plant operated by a renowned independent power producer. The project involved the extensive overhaul of a major cooling tower water pump, showcasing Conhagen’s ability to handle complex and demanding equipment repairs.
Objective
The primary objective was to restore the cooling tower water pump to optimal operating condition, ensuring minimal downtime for energy plant. This required addressing the immediate issue of the snapped line coupling, which caused the pump shaft and impeller to drop onto the suction bell, resulting in significant damage. Additionally, the project focused on enhancing the pump’s durability and performance while implementing long-term improvements to reduce future maintenance needs and costs.
Solution
Our team executed a comprehensive, in-shop repair service employing advanced techniques, which included:
3D Scanning, Reverse Engineering and Casting of a New Impeller:
- Service impeller was damaged beyond repair due to a snapped line coupling
- Conhagen mobilized an engineer to 3D scan and generate a reverse-engineered model of the impeller for casting
- All finish machining and balancing was handled in-house by Conhagen’s West Coast Division
Manufacturing Shafts:
- Manufacturing one new upper shaft
- Manufacturing one new lower shaft
Replacing Critical Bushings:
- Identifying and replacing worn-out bushings
Manufacturing and Installing a New Line Coupling:
- Fabricating and installing a new line coupling to restore functionality
Applying a Two-Part Epoxy Coating:
- Coating the suction bell, bowl, column, and head to protect against erosion and corrosion
Results
The overhaul was completed successfully, restoring the cooling tower pump to optimal operating condition and ensuring reliable performance. These improvements are expected to lower future maintenance costs and enhance efficiency. This project highlights Conhagen’s commitment to quality craftsmanship and innovative solutions, ensuring the longevity and reliable operation of essential equipment in critical industrial settings.