Enhancing Performance Through Flow Reduction

Operating a pump off its design point has many drawbacks. Inefficiency and wasting energy across a throttled valve bothrequire more horsepower than an optimized system. Running away from the best efficiency point increases risk of degradation, which may cause recurring premature component failures due to higher radial loads, hydraulic instability, and other influences. These factors negatively affect reliability while simultaneously driving up the cost of equipment operation and maintenance. For this reason, opportunities to optimize a pump are extremely beneficial and have a very short payback period.

The benefits of modifying pump performance to better match system demand were demonstrated in a recent project undertaken at a Gulf Coast refinery. The refinery had a single-stage, double suction (BB2) pump where the required output had been greatly reduced from the original design. The mechanical seals were repeatedly failing, which resulted in frequent maintenance and seal replacements. The refinery partnered with Hydro, Inc to perform a field evaluation of the pump and develop a design upgrade to increase reliability and efficiency.

Read the full case study in World Pumps’ January/February digital edition to learn what steps were taken to effectively reduce flow for this “bad actor”, returning the asset to reliable operation and significantly reducing the cost to operate the equipment.

Do you have an initiative to save energy and reduce the lifecycle costs of your equipment? Hydro’s Energy Edge is a comprehensive program where we work hand-in-hand with end users to understand opportunities for asset optimization and develop plans to execute on chosen solutions.

Troubleshooting Boiler Feed Pump Problems in the Field

Feed pumps are an essential piece of the steam cycle and their performance directly impacts the ability of the plant to produce power. As a complex component moving high-temperature, high-pressure fluid, maintaining critical fits and tolerances during construction and refurbishment is essential. It is equally important to ensure that field assembly and installation is performed with experience and precision.

Using experienced technical field advisors  (TFAs) when performing field work is even more critical as equipment ages. During a typical lifetime, equipment will undergo multiple refurbishments that may change the dimensions of the internal element, casing, and discharge head. For BB5 pumps, commonly referred to within the industry as barrel pumps, the barrel usually remains installed in the system and is not sent out with the internal element and head for refurbishment. As the installation settles, foundation degrades, and components undergo repeated thermal expansion and contraction, this barrel can lose some of its dimensional integrity.

One of the greatest pitfalls in performing a successful field installation is blindly trusting the installation and operation manual (IOM) supplied with the equipment. While this document provides useful guidance, any component changes that have occurred, both intentional and unintentional, are not reflected here. It is also important not to presume that pumps running in parallel have identical barrels or that internal elements are interchangeable. Instead of falling victim to these assumptions, best practices include completing a field dimensional analysis.

The value of capturing and recording critical data was proven during a complex boiler feed pump project at a coal-fired power plant. This project also highlighted the importance of adaptability and being able to react quickly to changing circumstances when performing fieldwork.

Read the full case study in Pumps & Systems February 2025 digital edition.

Learn more about Hydro’s Field Service capabilities here.

Capability Spotlight: Leverage a Global Network

From its first storefront on Diversey Street in Chicago in 1969, Hydro has grown into an expansive service network that supports rotating equipment users worldwide.  Our extensive footprint ensures that we can deliver our hallmark quality and exceptional customer service to clients across the globe.

Our geographic expansion has been accompanied by the growth of our engineering capabilities and our application knowledge. While all Hydro facilities are guided by the same processes and standards, we have also developed targeted capabilities, tooling, and experience in our individual locations to serve their local markets.  This service base is complemented by our centralized global engineering division, with experts in disciplines such as hydraulic design, metallurgy, and vibration analysis and troubleshooting.

By leveraging a diversity of expertise and resources, we can cater to the unique needs of each customer, ensuring timely and effective solutions that uphold our high standards of excellence. Some examples of niche capabilities within our network that can be leveraged by Hydro’s customers include:

Our growth has strengthened—not diminished—our commitment to local service excellence. Each service center combines on-site, dedicated engineering resources with established local supplier networks to deliver timely, effective support. We believe that communication is the cornerstone of successful collaboration, and we work hard to foster a culture of transparency and engagement.

Find your local Hydro service center here.

Facility Spotlight: HydroTex Dynamics

HydroTex Dynamics was founded in 1979 to meet a growing need for aftermarket service in the Houston area. By focusing on quality workmanship and cultivating strong relationships with customers, HydroTex Dynamics has become recognized as a premiere service location not only in the Houston area, but across the US. As an independent, they have expertise across OEMs and applications, with a strong focus on the power market and high-energy multistage pumps. The experience base and library of upgrades they have built support customers in increasing the reliability and life of critical equipment.

One of the key milestones in HydroTex Dynamics’ development was the time spent with Dr. Elemer Makay in the late 1980s and early 1990s perfecting the radial gap modifications (commonly known as A Gap, B Gap, and C Gap) on multistage diffuser-style pumps. Dr. Makay was a pioneer in battling impact loading and discharge recirculation in multistage pumps, failure modes that had historically caused high vibration, premature wear, and shaft failures for this equipment. He partnered with Jim Shaffer, founding partner of HydroTex Dynamics, in applying modifications that would combat these failure modes to drastically improve mean-time-between-repairs.

The radial gap modifications were applied to high energy boiler feed pumps across several Texas utilities with great success and are now regarded as a standard design for new boiler feed pumps. HydroTex Dynamics’ experience working with Dr. Makay on this modification provided them not only with an important understanding of factors that affect pump reliability, it also inspired a culture that paid attention to the many small details that add up to a smoothly running piece of equipment. This understanding has driven the service center’s high standards, including strict tolerances for critical geometries and balance, best-in-class assembly procedures, including a pit for assembling multi-stage pumps vertically, and an in-depth dimensional analysis that is the crucial first step in establishing axial centerline compatibility of every impeller within its respective diffuser.

Under the leadership of HydroTex Dynamics’ VP, Pete Erickson, they have continued to build upon this foundation by investing in advanced tooling, developing experienced shop talent, establishing a responsive field service unit, and fostering deep customer relationships grounded in trust and transparency. In 1995, they purchased the Pacific BFI line of BB5 pumps for North America, adding to their experience base in high energy, multistage pumps. They have on-site capability to perform 5-axis machining and can supply milled vane impellers with an industry leading turnaround time. While not currently certified, they are ISO compliant and follow all ISO practices.

One of the greatest strengths of HydroTex Dynamics is its people. The majority of workers in the shop have been with HydroTex between 15 and 30 years. Their hard-won experience and commitment to excellence is a cornerstone of the superior reputation that the shop has earned. By prioritizing communication and understanding each customer’s needs, HydroTex Dynamics delivers on their promise to provide one source of total support to pump users.

Contact us to learn more about HydroTex Dynamics or explore our global network.

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.