Case Studies
Case Study 1
Application: Produced Water
Story: A customer in Central Texas was experiencing a low flow situation from their horizontal pumping system. He was unable to get any help or direction from the original manufacturer. The problem could have been in the surface controlling variable speed drive, system inlet, pump, flow meters, downstream, etc; no one knew.
Solution: This customer called out DXP’s local experienced service technicians. After a thorough review of each of the horizontal components then using DXP's horizontal pump sizing program the problem was determined to be in the multi-stage centrifugal pump-end. DXP's wide range of multi-stage centrifugal pump-ends allowed them change out just the troubled centrifugal pump-end; without having to change any of the existing horizontal components. This customer was back up and running at full capacity in no time at all; thanks to DXP's superior service group.
DXP "Experts at Customer Driven Solutions"!
Case Study 2
Application: Produced Water
Story: Several customers in the Hobbs, New Mexico region were experiencing excessive vibration and premature wear in several of their horizontal pump-ends. To compound the problem, the shafts in their thrust chambers were continually breaking. When this happened it resulted in knocking out their primary power and shutting everything down. After multiple change outs of both the pump-ends and thrust chambers, DXP was called in to evaluate the complete system.
Solution: DXP thoroughly examined each component which was part of the horizontal pump package, including the surface controller. DXP determined there were two separate issues. First, the pump-ends needed to be enhanced, internally, to deal with the hostile fluids being pumped. DXP recommended installing all pump-ends with carbide bushing and sleeve supports to minimize pump wear. This also reduced vibration noise which was a contributing factor in seal wear and leakage. Second, DXP recommended changing the thrust chamber shafting from Monel to Inconel which is a higher strength shaft material. These two changes extended the life of the pump-ends and reduced seal wear. Also, the change in their thrust chamber shaft material eliminated further shaft breakage.
DXP "Experts at Customer Driven Solutions"!
Case Study 3
Application: Amine
Story: A prominent South Texas engineering and OEM company was responsible for constructing an Amine plant in Louisiana which would include multi-stage centrifugal horizontal pumps. The project called for detailed review, analysis and recommendations on a multitude of key pump components. They needed a partner who they could trust which had the in house resources to assist in completing this massive project, and within a specified time frame. Ideally they would like to work with a company who could offer pumping equipment, engineering, drafting, manufacturing, and complete service capabilities.
Solution: DXP was called in to be that partner. DXP's 100 years of pump experience, in-house engineering, drafting, and fabrication offered unique packaging capabilities not found in other companies.
In addition, DXP had recently launched their new horizontal centrifugal pump (h-pump) line called the HP-Plus. After careful review of the HP-Plus this customer acknowledged the superior skid design, multiple thrust chamber offerings, wide range of pump-ends, timely delivery of all orders to date, and the long history of DXP building pump skid packages. This was enough to satisfy even the most skeptical of customers.
In the end DXP not only completed it's responsibilities on or before the dead line, DXP was also beneficial in solving some piping issues which unexpectedly came up.
DXP "Experts at Customer Driven Solutions"!
Case Study 4
Application: Amine
Story: As of January 1, 2011, Federal regulations in certain gas plants and in certain states now require monthly reporting on all single seal horizontal pump applications. Not only will customers now be faced with more paperwork, they will also be required to build a total containment barrier around the entire unit when running a single seal configuration. In order to meet these new laws, customers' costs will go up for additional man hours in reporting plus the extra expenses for the barriers. Customers must either accept this or purchase high dollar / tandem seal configured designed equipment. Either way, this new regulation is adding to customers’ operational expenses.
Solution: DXP designed a new cost competitive, double seal configuration in which we have modified a standard single cartridge housing to accept a tandem seal arrangement utilizing a dry running seal secondary. This new design requires a minimal cost addition, for the secondary seal, while eliminating the need for monthly reporting and a total containment barrier. DXP's "customer first" attitude is constantly looking for ways to improve our customers' bottom line while maintaining our top quality field maintenance programs. Local services, engineering and manufacturing all contribute to providing our customers innovative pumping solutions.
DXP "Experts at Customer Driven Solutions"!
Case Study 5
Application: Produced Water
A customer in the Permian Basin in West Texas operating a competitor's horizontal pumping system contacted DXP on a Friday after their pump-end quit producing. When DXP arrived a short time later they determined the pump-end had a broken shaft. The customer elected to send the pump to DXP for repairs mainly because of the inability to get the original supplier to respond. The failed pump was shipped to Houston and on Monday it was disassembled. During dismantle, in addition to the shaft breakage a rag was found lodged in one of stages.
Solution: DXP machined a new shaft to replace the broken one and after careful examination of all components some of the stages were found to be worn in excess of tolerance. DXP had replacement stages in stock and changed out the bad ones. After rebuilding the pump it was placed on DXP's test bench. It tested perfectly. In addition to performance testing DXP performed one additional test which most competitors do not routinely do! We hydrostatically test the assembled pump. Hydrostatic testing is a necessary step and in this case the value of this test was proven. During the hydrostatic test DXP found a small imperfection in the housing. If this pump had been returned to the customer without hydrostatic testing, the customer would have been vulnerable to a leak that most likely would have developed.
Fortunately, DXP's thorough testing procedures caught this problem before it was shipped! The customer was thrilled when he was informed about the hydrostatic testing of his pump which caught a potential housing problem, but then expressed concern that sourcing a new housing could cause extended delays? DXP responded. The Houston repair center worked over time manufacturing a new housing and was able to ship the rebuilt pump by Thursday of that same week. Before shipping DXP hydrostatically tested the pump one more time making sure the problem was fixed. The customer was up and running with a completely rebuilt pump within one (1) week from their original call.
DXP's service and repair center used standardized internal repair and testing procedures that provided a more complete solution resulting in a better repair and minimal customer downtime. This is part of what we mean by the "Plus" of the DXP HP-Plus. Our goal is to provide more complete service which includes faster response, more comprehensive inspection, root cause analysis and testing, and expert removal and installation. With replacement parts on the shelf and in-house machining capabilities we also assure our customers the quickest overall turn-around time.
DXP "Experts at Customer Driven Solutions"!
Case Study 6
Application: H-Pump Servicing
Horizontal pumps (h-pumps) have been sold throughout the United States for a number of years. As they grow in popularity we find them installed in all types of applications and in just about every part of the country. While reliable, at some point during its life they will require some form of maintenance or repair. This is where the customer may encounter some difficulty. The core business for most h-pump providers centers on their downhole esp’s (electric submersible pump). Therefore, unless there is a large population of downhole pumps, in the vicinity, chances are great there may not be local service available. Service, by esp manufacturers, can be hundreds of miles away and take days, if not weeks, of waiting for their schedule to open up. Once service is on site spare parts may not be immediately available. This was the case in one of DXP's regions, South Texas. There are a number, and variety, of h-pumps installed and the customers were in need of help with everything from routine maintenance to minor parts replacement and trained expert service technicians.
Solution: DXP's Account Managers quickly recognized the situation and utilizing their local Corpus Christi service center proposed a “Horizontal Pumping System Preventative Maintenance (PM) Agreement”. This agreement is not exclusive to DXP's HP-Plus. It includes virtually all competitors. The DXP agreement calls out a number of check points and includes routine maintenance and parts replacement as part of the PM portion. All work is recorded in a summary report which includes observations and recommendations and is presented to company personnel. Scheduling is at the convenience of the customer and performed by qualified DXP HPS technicians. In addition, DXP can offer general PM training as well. The agreement has a fixed fee, including mileage and a per unit adder for additional HPS systems which are at the same location and serviced on the same day.
In the South Texas Region DXP was able to successfully implement preventative maintenance agreements for several reasons. First, we are a service minded company with an outstanding local maintenance center. Second, the HP-Plus product is a core initiative for DXP, a natural extension of over 100 years in the Rotating Equipment Business. And finally, DXP's trained sales and service staff are driven to identify customer needs and solutions. Having DXP service centers throughout the U.S. is just another example of putting the customer first.
DXP "Experts at Customer Driven Solutions"!