Engineering a Mainline Pump Package with Hydraulic Modification

POWER ZONE Case Studies | Project Highlights

This Ingersoll Rand 6×13 DA-8/6 Pump Package with a Toshiba 3500 HP Electric Motor is designed as a mainline pipeline pump in gasoline service for a well-known major pipeline company and PZE built an identical pump to serve as a backup spare. This mainline pump package was designed and built with extensive hydraulic modifications and the BEP was shifted right on the curve from the nameplate flow rate of 2560 GPM to the final tested BEP flow rate of 3584 GPM. This was done through a process of opening the volute areas inside the pump to accommodate more flow, and also modifications of the impeller vane profile to achieve higher flow rate, while at the same time not sacrificing head performance.

Along with the hydraulic modifications PZE also incorporated state-of-the-art materials into the rebuilt pump, including Boulden B-1050, which is a carbon fiber composite similar to Dupont Vespel CR-6100, for some of the internal wear parts of these pumps. This material is highly recommended in very dry or low lubricity fluid applications and very light hydrocarbons. This material is well known for reliability purposes as a pump can turn and run almost dry without catastrophic damage. The wear surfaces do not gall as can happen with metallic materials commonly used. Most importantly, when using the composite material, running clearances can be reduced, resulting in less recirculation and consequently, better efficiency.

This unit was built to API 610 specification and PZE conducted a complete witnessed FAT (factory acceptance test) on this unit in their state-of-the-art-testing-facility. Complete test curves, reports and performance analysis was provided as part of the final documentation. This unit is headed to the greater Dallas metroplex area and will be moving product down the line soon!

Package Specs

Main Package:

  • Brand: Ingersoll Rand 6×13 DAH-8/6
  • Flow Rate: 3640 GPM
  • Discharge Pressure: 1480 PSI
  • Suction Pressure: 200 PSI
  • Diff. Pressure: 1280 PSI
  • Fluid: Gas / Diesel
  • Specific Gravity: .72 / .84
  • Viscosity: TBD


  • CA6NM case material
  • 3600 RPM
  • 8 inch 900# RF suction connection
  • 6 inch 1500# discharge connection
  • 13.875 inch 422 stainless steel impellers
  • Case eye rings Boulden B-1050
  • Case hub rings Ni-Resist
  • Center and throttle bushings PERF design Vespel CR-6100
  • Throat bushing  Boulden B-1050
  • One piece center bushing
  • 410 stainless steel shaft material and shaft Jet koted at bearings
  • Radial sleeve bearings
  • 100 ohm Platinum bearing RTD
  • Metrix VTS-162 vibration velocity transmitters (4-20mA)
  • Thrust tilt pad Kingsbury bearing (ring in place for rundown) 
  • John Crane 8648VRS mechanical seals
  • Flexxor coupling by Coupling Corporation of America


  • Brand: Toshiba
  • HP: 3500 
  • RPM: 3600
  • Phase: 3 
  • Hertz: 60 
  • Volt: 4160 
  • Enclosure: WP II 
  • Frame 6810 
  • 120v space heaters
  • Sleeve self-cooled bearing
  • Copper bar rotor
  • 100 ohm Platinum bearing RTD
  • 100 ohm Platinum stator RTD (2 per phase)
  • VFD compatible (Includes bearing insulation and shaft grounding for VFD service)

Lube Skid:

  • 28 Gallon capacity
  • It is rated for 150 PSI
  • dual bypass filtration system
  • magnetic suction filter
  • A continuous pressure relief valve can be adjusted to the desired operating pressure
  • 100 OHM RTD to transmit discharge temperature
  • electric motor operates both the cooling fan and the oil pump to eliminate unnecessary sources of failure.
  • A tank heater is installed to heat the oil and avoid cold start ups
  • A float switch is installed to signal a low level shut down
  • An onboard accumulation tank allows for run down oil supply in the case of an unexpected shutdown. (This will avoid premature bearing failure.)

Power Zone Equipment specializes in hydraulic engineering, pump modifications, rebuilding pumps and specific mainline pump design and applications. Please contact us for all of your pipeline pump needs. Each of our pump packages go through a vigorous assessment process, customers are given detailed updates as the project moves forward, and our in-house testing facility ensures every unit is delivered fully ready for operation.

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