- Reverse Engineering
- Solidification Analysis
- Computational Fluid Dynamics
- Rotor Dynamic Analysis
- Stress Analysis
- Root Cause Analysis
- Pump Engineering Studies
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Hydro specializes in proven reverse engineering practices, and an engineering review comprises a key element of our quality manufacturing process. Reverse engineering differs from merely "replicating". Hydro pays particular attention to evaluating what caused the part to fail and defining the critical characteristics required to minimize the possibility of failure in the newly manufactured piece.
Hydro Parts Solutions offers difficult-to-source cast parts, such as impellers, diffusers, discharge heads, casings, bowls and suction bells. The process may include:
- Laser scanning and reverse engineering
- Solid modeling
- Hydraulic and metallurgical upgrades
- Solidification simulation
- Patternless casting/precision sand mold printing
- Casting metals that you specify
- Testing to verify pump performance
Reverse engineering is the examination, testing and analysis of a component to define and document all of the parameters and critical attributes necessary to manufacture, repair or modify it. Dimensions, tolerances, surface finishes and fit or clearance to adjoining items, are determined. Hydro's process also includes an analysis of the chemical and physical properties of the material of construction as well as its hardness and residual stresses.
While accuracy, thoroughness and technology are important elements of reverse engineering, it is Hydro's pump-specific engineering knowledge, understanding and experience that distinguish and define our process.
A casting model and drawing is created with allowance for machining stock and a solidification analysis is performed on the casting model, which enables Hydro's engineers to design an optimal mold package.
Hydro utilizes Computational Fluid Dynamics software to evaluate and predict flow patterns within a pump, allowing us to project performance under a given set of circumstances.
This tool provides the opportunity to test many variations in an effort to attain an optimal design before physical prototyping. CFD allows Hydro to not only evaluate more design alternatives and opportunities for performance improvement, but also offers a faster turnaround time.
If a pump rotor is not properly balanced or if the running clearances are too open, the natural frequency of the rotor can match its running speed and create vibration. This phenomenon can create catastrophic failure in a multi-stage pump.
Rotor dynamic analysis can be performed on any pump rotor to determine the lateral and torsional critical speeds. This analysis in turn leads to harmonic analysis and transient analysis. Using this sophisticated software tool, Hydro can perform rotor dynamic analysis and recommend upgrades to increase the critical speed and reduce the vibration.
In addition to vibration created internally by the condition of the rotor itself, vibration can be created by the driver. If the torsional frequency of the driver matches the running speed of the rotor, there will be resonance and amplification of applied torques. Hydro can also perform transient torsional analysis of any pump rotor under different motor torque conditions. Such analysis can lead to recommendations to improve the factor of safety against shear.
Stress analysis is an engineering discipline that determines the stress in materials and structures when subjected to specified static or dynamic forces or loads. It is performed to determine whether a structure can safely withstand the specified forces.
Hydro performs stress analysis of the pump pressure boundary components in accord with ASME guidelines. Stress analysis provides the data to optimize the structure or component against the forces being applied. In many cases it is found that bolt thickness and sizing is more than required and can be optimized by performing finite element analysis.
To identify root causes of pump problems, Hydro combines our very thorough and detailed inspection process with an evaluation of a pump's field operating conditions and maintenance history. This more in-depth approach can prevent costly forced outages by revealing latent conditions that may be causing repeated failures.
Hydro's engineering team has the knowledge and experience to analyze the existing problems and to recommend a quality solution based on sound engineering analysis and proven practices.
While many problems can be identified during a physical inspection of the pump when it is removed from service during either a planned or unplanned outage or turnaround, other more complex problems may require an extensive analysis of the pump and its system (driver, piping, foundation, change in application, operations and so on).
Hydro has the experience and resources to perform such engineering studies or to participate as part of a consulting engineering team to analyze complex pump and system problems.