• project information
  • employer Bandar Abbas Oil Refinery
  • project delivery date 1395/01/20
  • project name Four-stage pump
  • Quality excellent

Four-Stage Pump

The Bandar Abbas refinery uses the four-stage pump to provide 30 bar pressure and 130 m2/h of fluid. Originally manufactured in Worthinton, Germany, this company has managed to reverse-engineer, redesign, and manufacture it with over 60 parts using different technologies. It is currently in use in Bandar Abbas refinery. In addition to reverse engineering and indigenous production, the body material has also been changed. The foreign model's body was made from A216 WCB, which was changed into ASTM 316 stainless steel for corrosion resistance and increased lifespan. This is among the most complex centrifugal pumps with four propellers and replaces 4 pumps in series.

Product Technologies

To fully design and reverse-engineer the 4-stage pump according to the foreign model, the sample pump was quickly disassembled, itemized, and reverse-engineered. The design and manufacturing method of each component was included in a technical manual. Then, it was manufactured from plans without access to the original equipment. Since comparison of new and original equipment wasn’t feasible, the company had to start reverse-engineering with a used component, which made designing and mapping with correct tolerances very difficult and complex. Meanwhile, modeling and casting, especially from the aforementioned material, was also complex and required unique technologies. First, 60 parts were manufactured and assembled with different hardness levels. Due to manufacturing complexity, especially the body, assembly conditions, and tolerances, it is the first pump to be produced in Iran. To improve product lifespan, a new casing material was designed and the body was converted from simple carbon steel to 316L stainless steel. Notwithstanding annual inflation of raw materials and given manufacturing within a year, it costs 20% of the foreign variant.

1

2

3

4

Product Application

  • Four-stage centrifugal pump with four propellers
  • Produces 30 bar pressure and 130 m2/h flow

Manufacturing Process

  • Disassembling and itemizing 60 parts
  • Mapping with measurement tool and producing digital cloud of points
  • Map correction and tolerancing components
  • Software part assembly and re-correction
  • Technology and manufacturing method for each item, including modeling, casting, and supplying
  • Raw material
  • Producing the technical manual
  • Making each item according to the specified manufacturing process
  • Procuring standard washer, gasket, and other items
  • Assembling items
  • Hydrostatic testing

Design and Manufacturing

To design and reverse-engineer the pump, the model in use was first disassembled and itemized, all parts were digitally mapped in 45 days, and the original equipment was reassembled and returned.

Then, each item was separately designed in SolidWorks followed by matching and tolerancing.

  • Designing and producing maps and the manufacturing process
  • Manufacturing entails casting, cutting, various turning and boring machinery, and CNC milling, radial drilling, and more.
  • Rotor dynamic balance assembly
  • Assembling all components after ensuring sealing and excellent rotation

Product Testing

The tests were conducted in-house.

Quantometry test according to the technical manual

The customer's required tests are carried out in the customer's factory.

The product's mandatory standards

  • The upper and lower half and propellers made according to the ASTM 316L standard
  • Wirings, shafts, and bushes made with the purchased raw materials
  • Hydrostatic body testing up to 40 bar after full assembly
  • Application test on site
پمپ چهار مرحله ای