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Modern 3D CAD tools used to package pumps speed up design and manufacturing processes
Pump package as
a CAD model and on
the shop floor.
tion, packaging design and machining. In Manufacturing in parallel or drawings generated from the 3D CAD
the past, the package had to be assem- These modern design processes allow system.
bled to determine the exact locations of engineers to perform multiple tasks in The current practice is to fabricate a
piping and supports. After that, disassem- parallel and only lay down a baseplate small section of the pipework and fit it
bly was necessary, followed by final onto the shop floor when all items have to the pump. The fitter then checks the
machining and painting of the baseplate, been manufactured and are ready to fit dimensions, takes the pipe off, and fabri-
and final assembly of the package for the onto the skid. cates the rest of the pipework. The piping
e customer. Today, up-to-date 3D design In todays practice, the baseplate can is then refitted, checked, and adjusted.
it programs for the pump package, includ- be fabricated, the bare shaft pump can The completed pipework is then taken off
y ing the piping, significantly reduce the be machined and assembled, and the again for x-ray or other examination,
e lead time required to completely package pipework can be prefabricated simulta- pressure test, and cleaning. Once these
e a skid within the assembly shop . neously using the piping isometrics processes are completed, the pipework is
r
n 3D CAD pictures
and corresponding
e
photos of a pump.
i-
w
a-
s
n
inspection and cleaning, prior to the skid the integration of the pump sets in the
arriving . The pipework is fitted only surroundings of e.g., a power plant
once when the skid arrives and only small with regard to pipework, wiring, high-
adjustments are made before the final voltage connection, as well as instrumen-
inspection. tation and control.
This approach reduces the overall lead- If such models are created during the
time for the assembly of a pump package inquiry phase of a project, customers can
th
from 12 to 7 weeks on average. This get a very vivid impression of how the
improvement is only possible if all sub- pump will look and, at the same time, can
components are in place and ready to fit receive a large amount of reliable data
as soon as the baseplate enters the shop. relating to requirements for space and T
Three-dimensional design also offers engi- hook-up to power supply. Because such p
neers the possibility to analyze addition- custom models already include a lot of b
Modern 3D CAD and visualization tools allow the pipework al space requirements, like the room definite information, Sulzer Pumps is able o
(bottom) to be prefabricated prior to the skid arriving.
needed for ventilators and silencers of a to complete them very quickly in the o
noise hood, service openings, or accessi- event of an order and thus submit a
bility to the seal systems for service. The assembly drawings with binding dimen- m
engineers need to provide sufficient clear- sions within a very short time. o
ance for stud, nut, and wrench for seal Additionally, sub-suppliers and clients s
assembly and removal. Clearance checks alike can use the 3D visualization p
in the virtual reality of a fully homolo- provided by Sulzer Pumps in their down- t
refitted for final inspection. This proce- gous 3D model on the computer allow stream engineering activities, which saves b
dure can take up to five weeks and can for the planning of additional measures them the effort of creating models from
only be performed once the actual pump to ensure access for such tasks. 2D drawings (that were previously made P
is available for fitting. available). As these detailed models T
Supporting customer processes provide the ability to recognize exactly d
Speed up of fitting An obvious strength of 3D design the space conditions around the unit, such f
Modern production processes at Sulzer programs is the visualization of the pump as intersections with process piping or f
Pumps using 3D CAD and visualization assembly at a very early stage of the room for safety runways, the Sulzer 3D p
tools ensure that the pipework is com- project . This feature is helpful for the models support civil engineering and s
pletely prefabricated, incorporating all the planning of the whole plant, as it supports plant design processes. C
h-
n-
e
n Complete boiler feed pump set for an EPR Nuclear Power Plant. Thanks to modern CAD tools,
the setup of the machines can be planned long before they are actually in the power plant.
e
n
a
d Three-dimensional modeling speeds up an evolutionary type and takes advantage additional equipment, will increasingly
h processes not only on the customer side of over 30 years of operating experience speed up design and manufacturing
f but also on the vendor side. Other uses acquired by French and German design- processes for pumps and also support
e of the model include preliminary design ers and operators. The reactor will customer processes by facilitating the inte-
e of test bed arrangements. The pump consume 17% less fuel due to the use of gration of Sulzer products in the clients
it assembly can be brought into the more efficient assemblies and higher plant layout.
n- modeled test bed area for preconfiguring turbine efficiency than previous reactors.
of the test bed piping on the computer This improvement, along with refueling
Andy Thomas
s screen. This computer-aided planning outage times, which are two to three times Sulzer Pumps (UK) Ltd.
n process reduces the time needed for the shorter, will increase annual power LS11 8BR Leeds
United Kingdom
n- test setup when the actual test runs must output by 36% compared with current Phone +44 (113) 270 5790
s be performed. reactors. Sulzer Pompes France has to andy.thomas@sulzer.com
Sulzer HPT Multistage Barrel Casing Boiler Feed Pump in a thermal power station in Lippendorf, Germany.