West African team repairs Shell Nigeria’s contaminated pumps

Bosch Rexroth Ghana, with the help of Bosch Rexroth South Africa, has completed repairs to contaminated HPU double pumps on the Framo Crude Oil Pumping System belonging to Shell Oil and Exploration in Nigeria. The hydraulically driven submerged cargo pumps are used to provide safe, efficient and flexible cargo handling of liquid cargo. This project was completed ahead of deadline and provided a unique opportunity for Shell Nigeria to reduce its total cost of ownership, as well as improve maintenance turnaround times.

Collaborative repairs

In January 2020, Shell Nigeria sought out repairs for 9 of its HPU double pumps and requested that Bosch Rexroth Ghana do the job. The Ghana team drew on the technical expertise of Bosch Rexroth South Africa, led by Repairs Manager, Ian Kidson, and supported by workshop technicians Ronald Seller, Eugene Roos and Allan Page. With a total hydraulic investigation and inspection, the team found that all pumps were contaminated.

Repairs began in July 2020, during South Africa’s lockdown. Due to lockdown restrictions, the factories were not able to produce the required spare parts immediately. Repair teams decided to carry out the job in stages, as spare parts became available, which allowed them to complete the repairs ahead of the stipulated project timelines.

Beating deadlines

Shell continued its operations throughout this period, by using 2 spare pump units. The required repairs were critical, as the pumps were part of an asset which pumps crude oil from the oil production platform into floating vessels – essential to Shell’s operations. Bosch Rexroth prioritised the repair plan and ensured that Shell’s operations would not be disadvantaged.

The team completed the repair work, which included de-assembly of the double pumps A4VSO; stripping and analysis; identification of faulty components and the collection of a detailed inspection report. “Repairs were completed on the first four pump units in December, which was sufficient in preventing any downtime to Shell’s operations,” explains Alex Booth, Bosch Rexroth Regional Manager: West Africa.

The remaining 5 pumps were repaired and re-certified in January 2021, with the project concluding on 28 January 2021 (30 days earlier than the expected completion date).

Successful outcomes

This repair project is a huge success for the Bosch Rexroth West Africa team, serving as a milestone for Bosch Rexroth’s Nigerian business development as it pursues growth in the large and competitive oil & gas sector. “We are pleased to report that the pumps were repaired and tested to OEM standard, ahead of the project deadline,” explains Alex.

Guaranteed operation going forward

The pump repairs carry a 6-month warranty and are supported by an agreement between Shell and Bosch Rexroth to continue working together.

For Ghana’s workshop team, this project also proved a very successful training project. “We provided hands-on training on the stripping, quoting and rebuild process as well as the testing of the pumps,” says Alex.

The Bosch Rexroth West African team repaired Shell Nigeria’s contaminated pumps 30 days ahead of schedule.

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