Hydro, Inc. is pleased to introduce Hydro Richards, its newest service location in Canada. The facility is located in Port Coquitlam and is conveniently located close to the TransCanada Highway, US Border and Vancouver International Airport. Hydro Richards specializes in pump repairs and has extensive experience in the manufacture of machined pump parts and babbitted bearings, with shafts being a solid area of expertise. They also provide special overlays and coatings to increase component life. Hydro Inc has added its complete array of pump services to strengthen their product and service offerings in the Pacific Northwest.
For more information regarding the services and capabilities of Hydro Richards, please visit our website at: www.hydrorichards.com
Additive manufacturing also improves geometric tolerances.
Written by: Jesse Stinson (Hydro Parts Solutions) & Werner Barnard (Hydro Inc.) Publisher: Pumps & Systems / March 2, 2015
An increasing number of industrial plants are reducing the spare parts inventories stored at their facilities. At the same time, they are replacing fewer pumps because of capital constraints and have determined that remanufacturing existing equipment is the best path forward. Many of the pumps within these facilities have exceeded 50 years of service. This drives the need for replacement parts and, in some cases, emergency replacement parts. Considering the age of these pumps, the replacement parts from the manufacturer are likely obsolete and may not be easily available. Further complicating the situation is the location of manufacture. Many cast parts are manufactured outside the U.S and have long lead times.
To address these challenges, many companies are developing technologies to meet the specific and growing demands of the industry. Many of these advanced tools, including coordinate measure machine (CMM) technology, allow for quicker emergency repairs, faster deliveries and higher quality pump parts.
Image 1. New bronze impeller casting (Images and graphics courtesy of Hydro Inc.)
Figure 1. Reverse engineering raw scan data
Emergency equipment repairs are common throughout the industry. Having fewer spare parts makes this classification of repair more challenging. Standard equipment repairs typically take six to eight weeks, while emergency repairs must be completed within one day to three weeks, depending on the severity of the situation.
This type of repair often drives the need for rapidly supplied cast parts, which traditionally require long lead times because of the use of wooden tooling to create the mold to manufacture the casting.
Recent advancements in 3-D technology, known as additive manufacturing, allow the cast parts manufacturer to meet customer demands by eliminating the need to create traditional tooling.
Hydro CEO and Founder, George Harris (at podium), and Governor Pat Quinn (left)
CHICAGO – As Illinois’ unemployment rate continued to fall to its lowest point in six years, Governor Pat Quinn today visited Hydro, Inc. in Chicago to discuss the state’s ongoing economic recovery. Over the past six months, Illinois’ unemployment rate has fallen faster than any other state in the country. Illinois’ unemployment rate dropped for the sixth consecutive month, from 6.8 to 6.7 percent in August, its lowest level since August 2008 and lower than when the Governor took office. Today’s event is part of the Governor’s agenda to create jobs and drive Illinois’ economy forward.
“Hardworking women and men across our state are back on the job and today’s numbers are proof that Illinois’ comeback continues,” Governor Quinn said. “More people are working today than at any time in the past six years and that is thanks in part to companies like Hydro who are staking their future right here in the Land of Lincoln. While we have more work to do, we are getting the job done and Illinois is headed in the right direction.”
The Illinois unemployment rate fell in August for the sixth consecutive month to reach 6.7 percent while employers created 13,800 jobs, according to data released earlier today by the U.S. Bureau of Labor Statistics and the Illinois Department of Employment Security. This is the lowest rate since August 2008 and the drop from 9.2 percent one year ago marks the largest year-over-year decline in 30 years.
We are pleased to announce that Dr. Gary Dyson will be joining Hydro Companies. Gary will be headquartered in the UK in our new engineering center, Hydro Global Engineering Services. This engineering center will provide the highest level of support to the Hydro network of service locations and will help solve the complex engineering problems associated with pumping equipment.
Hydro Engineering Services will provide a system that all locations can access so that we can continue to help our customers modify, upgrade and re-rate their equipment. He has expertise in hydraulic and mechanical engineering across many manufacturers and industries.
Dr. Gary Dyson has spent his entire career working with rotating equipment. He gained his PhD from Cranfield University for his work using Computational Fluid Dynamics to predict the time dependent nature of pump hydraulic performance at off-design conditions. He has used his hydraulic expertise to help many customers to re-work their equipment to improve reliability, performance and efficiency. During his time working for Clydeunion, Weir Pumps, David Brown Pumps and Mather + Platt Pumps, Dr. Dyson has developed expertise on equipment from complex multi-stage barrel pumps to single stage OH2 machines. Alongside support for Centrifugal pumps Hydro Global Engineering Services has also added expertise to support the requirements of their customers on reciprocating machines. They can advise on plunger pumps and direct acting pump repairs, upgrades and performance modifications.
We welcome Gary and his great wealth of experience to the Hydro team!
Written by: Greg James, Hydro Australia Publisher: Pumps & Systems / October 2014
Station History
Eraring Power Station, located in the coal belt area at Lake Macquarie on the central coast of New South Wales, began generating in 1982, with all four units commissioned between 1982 and 1984. Formerly state owned under the banner of Eraring Energy until mid 2013, the station is now owned by Origin Energy, one of Australia’s largest electricity generators and retailers.
The power station underwent a significant upgrade during 2010 to 2012, increasing the output of all four generating units from 660MW to 720MW each. Eraring is the largest generating unit in the Origin group and has established itself as Australia’s largest power station since the upgrade.
Condensate Extraction Pumps
The pumps are the standard arrangement of condensate extraction pump used in the power generation industry: underfloor, vertically mounted, canned design, 4 stages with a double suction impeller and inline suction and discharge ports. Each of the four generating units has two 100% duty pumps, driven by a 1850kW 4 pole, electric motor.
Problems
For more than a few years, the life of the thrust bearing has been subjected to scrutiny after causing numerous premature failures and constant concern for the Station Operators, Maintenance Engineers and Management. The thrust bearing design was typical for the period that the pumps were manufactured, tapered back to back roller design incorporating both thrust and radial loads and the drive coupling configuration as part of the bearing cartridge.
Station Engineers had been researching the upgrade design options for a period of time, calling on the original equipment manufacturer, aftermarket service centres and bearing manufacturers for input and options to overcome this troublesome plant and work towards the best possible solution.
Contract Overview
In 2012, Eraring Energy released a tender for the upgrade project to several service providers. The project included a sizeable work scope including design and supply of a new white metal bearing cartridge with an appropriate pedestal and several other new components.
The contract specifications require maintaining the same pump drive couplings, electric motor, mechanical seal cartridge and as many of the original pump components, meaning there was substantial engineering work required by the Hydro Australia Engineers.
Contract Award
A contract of this size was sought after by several original equipment manufacturers and Hydro Australia Pty. Ltd. located in the Gippsland region at Morwell Victoria was awarded the contract late in 2012. The contract runs for a period of 4 years with the first pump installation completed in April 2013 and the final pump due for installation in 2016.
Additional Requirements & Spare Pump
With the knowledge and experience of Hydro Australia with the supply of engineered spare parts, a major undertaking was to supply and a complete new discharge head, a first for Hydro Australia. The 2.5 m high and 1.7 m wide discharge head is the most significant component of the pump as it ties everything together. Other new components were manufactured by Hydro Australia including impellers, stage cases, wear rings, couplings and shafts. The new components complete with the stations spare parts, enabled a complete spare pump to be manufactured. This spare pump gives flexibility and relieves time critical exchanges and on the run maintenance. Continue reading →
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