Capability Spotlight: Verify Pump Performance

Performance testing in a controlled environment is an important tool for pump designers and users alike. Understanding how the pump will react hydraulically and mechanically throughout the full range of operation enables improved equipment reliability, optimized efficiency, and reduced operating and maintenance costs.

In the aftermarket, performance testing helps equipment owners:

  • Identify discrepancies between actual and expected performance before equipment is returned to the field
  • Validate acceptable mechanical performance of critical equipment post-repair- before significant damage occurs
  • Confirm effectiveness of hydraulic modifications by validating that theoretical performance is accurate and repeatable

To support end users in understanding equipment health and performance, Hydro built its Certified Performance Test Lab at the HydroAire 40th Street service center in Chicago. Our test lab was the first to be certified by the Hydraulic Institute’s Pump Test Lab Approval Program, and all testing is completed in accordance with Hydraulic Institute (HI) 14.6/40.6 and/or API 610, ASME, or ISO, as relevant.

Hydro’s test lab is tailored to the demands of the aftermarket, focusing on flexibility and data transparency. Instead of moving the piping to the pump, Hydro’s Test Lab moves the pump to the piping:

  • A 36’x20’ baseplate allows for quick and customized installation
  • A multitude of piping inlets/outlets suitable for a wide range of nozzle sizes
  • Accommodates hundreds of different pump configurations
  • Allows multiple pumps to be staged for testing simultaneously

This flexible configuration enables Hydro to set the standard for turnaround times on aftermarket testing. In addition to common offerings such as hydraulic performance, mechanical performance, NPSH, endurance, and critical speed testing, Hydro has performed custom testing configurations to help end users understand specific problems. This is illustrated in the Test Lab’s inaugural test, which was a series of tests for a nuclear safety-related service to help an end user prove to the NRC that this service was capable of handling transient air voids in the system.

Learn more about Hydro’s Certified Performance Test Lab or contact us to schedule a pump test.

Podcast: Picture Pump Efficiency in Terms of Trees and Cars

When it comes to pumping systems, efficiency must be viewed in terms of measurable savings taken as a whole-system approach. Organizational buy-in and leadership support are crucial.

Tune in to Dr. Gary Dyson’s recent conversation with editor Traci Purdum on the Chemical Processing Distilled podcast where he helps us understand how best to achieve efficiency and how pump users can update their thinking when approaching the subject.

Read Chemical Processing’s Industry Perspective or listen to the podcast.

 

Pump System Optimization Guide

By some industry estimates, the average pump in an industrial production facility is operating at less than 40% efficiency, and 85% of pumps are not optimized to their system. This subpar performance translates to real money lost in the form of higher energy costs and premature wear and tear on overstressed valves. This excess stress on system components can lead to shorter mean time between repairs, higher maintenance costs and more unplanned downtime.

To learn expert insights on optimizing your pump system for maximum efficiency and cost-effectiveness, download the Pump System Optimization ebook that Hydro co-sponsored with Plant Services magazine.

 

Strategies for Improving Life & Performance of Aging Equipment

Many of our aging facilities are still using the pumps that were purchased and commissioned during plant construction. Despite the age of this equipment, effective maintenance strategies and upgrade opportunities can extend useful life for decades more. Older pumps are often more robust than current designs, which take advantage of new manufacturing technologies to reduce the raw materials needed for construction. However, vintage equipment has its downfalls as well. It is important to understand the challenges we face when operating and maintaining vintage equipment so that we can stay ahead of potential sources for decreased reliability.

These challenges were at the forefront of an improvement project undertaken by a Canadian pulp mill. Most pulp and paper mills in North America have been in operation for decades, and many are still running with the original equipment. This facility had several BB2-style makeup liquor pumps (MULP) that were experiencing a low mean-time-between-failures (MTBF). To increase pump life and reduce the risk of unexpected downtime, the pulp mill approached Hydro’s Scotford service center for support in identifying the root causes of degradation. Hydro Scotford combined a thorough inspection process with experience in upgraded designs and materials to bring the MULP system reliability back to an acceptable level and improve overall performance. The major focus points of this project – standardization, material upgrades, and improved tolerances – can be applied to aging installations in all industries.

Read the full story in our recent case study published in World Pumps magazine.

Capability Spotlight: Utilize On-Site Expertise

In the intricate world of industrial operations, pumps play a pivotal role. When a pump fails, it can disrupt entire production lines, leading to significant financial losses and safety hazards. Regardless of the quality of equipment construction or refurbishment, a proper field installation is critical to ensure reliable performance and achieve maximum life.

Unfortunately, the industrial sector is currently facing a significant challenge: the retirement of a large cohort of experienced workers. This exodus has created a skills gap, particularly in areas like field service. The expertise and knowledge these seasoned professionals possess are invaluable, and their absence can leave companies vulnerable.

That’s why partnering with a skilled and experienced field service team is critical.

Hydro’s field service technicians and technical field advisors (TFA) are highly knowledgeable professionals with experience over a wide range of pump applications, manufacturers, and models.  This experience is a critical factor in ensuring that field projects are performed effectively:

  • Hydro’s technicians are pump subject matter experts and have an extensive understanding of pump systems, their components, and common issues. This knowledge allows them to diagnose problems quickly and accurately.
  • Experience has provided our field service technicians with the ability to think quickly on their feet and develop exceptional problem-solving skills. They can handle unexpected challenges, devise creative solutions, and minimize downtime.
  • Experienced technicians are more efficient at their tasks. They know the best practices, processes, and tools to use, resulting in faster turnaround times without compromising the accuracy or quality of the field activity.

At Hydro, our on-site services team is comprised of subject matter experts in their field. Their knowledge across OEMs and industries is combined with Hydro’s extensive library historical data and global engineering support. It is also augmented by our field engineering division, which provides on-site performance and mechanical testing and troubleshooting. This powerful combination allows us to provide tailored solutions for your pump problems, enhance your reliability, and reduce your pump-related operating and maintenance costs.

Meet Hydro’s Technical Field Advisors:


Our Field Service Offerings

Hydro’s comprehensive field service offerings include:

  • Installation and start-up
  • Field machining and onsite welding
  • Turnkey services
  • Project management
  • Vibration analysis
  • Laser alignment
  • Pump system troubleshooting
  • Field engineering
  • Emergency field response
  • Hands-on training

Read more about how Hydro’s On-Site Services team has supported end user’s in the field with this case study from the Nuclear Power industry.

Contact us to discuss scheduling on-site support.