Blog

Capability Spotlight: Verify Pump Performance

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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

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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

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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.

 

Capability Spotlight: Utilize On-Site Expertise

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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.

Capability Spotlight: Rethink Your Parts Strategy

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The Critical Parts Landscape is Changing.

With the advent of innovative pattern making and additive manufacturing, end users have more options than ever before when it comes to parts supply. When faced with these exciting changes, it is important to develop a parts strategy that takes advantage of new technology while still reducing risk of component failure or unsuitability.

At Hydro Parts Solutions, we combine innovation with hard-earned experience in pump engineering, reverse engineering, materials, and casting.  Knowing that reverse engineering is far more complex than laser scanning and replication, they rely heavily on this experience and the knowledge of Hydro’s engineering network to verify critical dimensions, account for wear of the scanned component, upgrade tolerances, and provide a part that is better than the original.

By cultivating strong relationships with local foundries, Hydro Parts Solutions can provide expedited lead times while maintaining control of product quality throughout the manufacturing process. They adhere to strict process control procedures, including providing standardized parts numbers and generating drawings for every part.

Every job completed by Hydro Parts Solutions is passed through multiple levels of engineering and inspection checks, from model development through pattern creation to final machining and equivalency analysis.   This gives you confidence that the parts supplied will provide safe and reliable service.

As pump experts, Hydro has the experience to reverse engineer and supply complex hydraulic components and the resources to diagnose design problems and suggest targeted upgrades. Hydro routinely upgrades vintage equipment with proven design component design upgrades that counteract known failure modes. Our global engineering team works closely with our parts division to perform hydraulic modifications that increase efficiency or help end users meet changed system requirements.

The end result? Shorter lead times and longer component life.

Explore Hydro Parts Solutions’ state-of-the-art parts case studies.

Discover Hydro Parts Solutions here.

Contact us for a parts quote.