Sulzer’s collaborative
approach keeps production flowing for offshore platform
|
Location |
Brazil |
| Industry | Oil & Gas |
| Key Services |
|
Lead time
4 - 8
months
fast and predictable delivery lead times
Unplanned shutdowns
0
no production losses and lower maintenance costs
Repeat failures
0
repeat failures. Long term solution: eliminates repeat failures for sustained performance
Pump lifespan
10
months
uninterrupted pump operation delivering reliable uptime and longer equipment life
Persistent vibration issues risked production shutdown on an offshore platform
The customer’s storage tank pumps suffered recurring failures that would lead to full tanks and operational shutdown if left unchecked.
When slop and other storage pumps started failing, the OEM supplied replacement parts which also failed. The OEM’s lack of presence in the region, combined with short lifespan of the new parts, made it clear that the customer needed a faster response and a partner they could trust to deliver lasting results.
The project covered:
- Ten pumps including three models and sizes
- OEM pumps typically failed within three to six months
- Repairs to address excessive vibration caused during equipment assembly, commissioning and startup processes
We deliver reliable solutions our customers trust
We provided a full overhaul and targeted retrofit, including the replacement of intermediate bushings with material better suited to the application’s operating conditions. The customer needed reliable operation and extended equipment lifetime, which guided our engineering approach.
This was a technically complex project with varying lead times ranging from four to eight months due to reverse-engineering requirements, detailed analysis, component manufacturing and material availability.
Project scope:
- Complete pump overhauls
- Reverse engineering using laser scanning and advanced data processing
- Material analysis and retrofit execution
- Commissioning and start-up performed by Sulzer expert engineers
In total, the project involved:
- Collaboration between workshop teams and Field Services
- Offshore commissioning and startup support
- Project success rested on helping the customer avoid lengthy production losses
Precision engineering delivers a reliable solution
Sulzer’s engineering expertise significantly improved equipment reliability. The pumps from the initial phase have now been operating for over ten months without issues. This improvement in operational availability has helped reduce unplanned downtime and prevent production losses, representing a significant benefit for the customer.
Time is also a critical factor for the customer, as pump unavailability can lead to full waste tanks which would halt production. The shortest lead time we achieved was four months and the longest was around six months. We received the first pumps in 2024 and the last ones will be delivered in Q1 2026.
Sulzer is the benchmark in excellence for manufacturing parts, overhauls and onboard services for vertical pumps.
Benefits at a glance:
- No unplanned shutdowns
- Removed risk of production losses
- Lower ongoing maintenance costs
- Fast and predictable 4–8-month delivery lead times
- Removed cause of repeat failures for improved efficiency
- Improved reliability across 9 pumps
Bruno Camargo - Senior Sales Engineer, Sulzer
A proactive root cause analysis and full overhaul of all 10 vertical pumps delivered a reliable, long-term solution that eliminated repeat failures. The customer came to us for improved performance and to avoid production shutdown. We delivered both as well as lower maintenance costs and extended equipment life.
