Re-engineering System Reliability

A US fertilizer plant was experiencing recurring reliability problems with its horizontal multistage boiler feed pumps. The series of repeat failures motivated the owner plant to consult with a widely-known unbiased ­­­­aftermarket pump service provider. Previous experience with this company’s Texas facility gave the plant confidence that they had the capability to troubleshoot the problem and provide a solution. This type of supplier has been classified as a “CPRS”— Competent Pump Repair Shop, because their worldwide affiliates are staffed by specialists who have the fullest support of pump engineers at the company headquarters.

The aftermarket pump service provider performed a failure modes and effects analysis (FMEA) that took into consideration historical failure information and included an independent engineering analysis of the operating conditions. A review of the system history uncovered that the fertilizer plant had originally been designed with two 100% pumps. When the system was uprated, increased output requirements necessitated that both pumps operate in parallel to meet the new demand. Based on this information, the FMEA determined that the most probable failure mechanism was discharge recirculation caused by low flow operation.

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Unearthing the Root Cause of Vibration Issues

recently constructed fertilizer plant was experiencing significant vibration problems on their brand new UAN Solution pumpsThis vibration forced the plant to take the equipment out of service.   

The site was unable to diagnose the root cause of this problem on their own and the unreliability and resulting unavailability of this critical equipment was causing significant stress on the new plant. They heard through another fertilizer plant that a global aftermarket pump service provider had been able to diagnose and remediate their pump problems with great success. The site reached out to this aftermarket pump service provider to help identify the issue and provide solutions.   

The pump was shipped to the aftermarket pump service provider’s Chicago repair shop to perform a thorough disassembly, cleaning, and inspection (DCI). The service provider’s engineering team reviewed the original pump design and historical vibration information provided by the plant. Between this review and the DCI results, sufficient evidence was gathered to perform a root cause analysis (RCA) that explained the aberrant behavior of the problem pumps. The pumps were then re-engineered to eliminate the diagnosed problem and provide the plant with reliable operation.   Continue reading

The Hidden Dangers of Shaft Stiffness

The pump shaft is the central component of the rotating element and is responsible for transmitting energy to the rotating components. The shaft carries the impellers, sleeves and couplings for the rotating element assembly. The stiffness of the combined assembly is responsible for ensuring that the pump stationary components do not come into contact with the rotating components.

Unfortunately, this is not always achieved and many pump rotors cannot be described as classically stiff. This can have dire consequences for machine reliability, particularly if, during the rotor build process, the technicians are not aware of the subtleties of the machine design.

Source: https://www.pumpsandsystems.com/hidden-dangers-shaft-stiffness

Meet Centaur, Hydro’s Wireless Condition Monitoring Solution

Hydro, Inc. introduces Centaur, its Wireless Condition Monitoring Solution. Centaur provides users with remote monitoring allowing for operators and engineers to observe equipment performance in real-time enabling predictive analytics, vibration monitoring, and temperature readings to optimize critical asset maintenance strategies.

Centaur offers advanced data analysis support, backed by Hydro’s diversified and unbiased pump knowledge base, which spans across a broad spectrum of manufacturers and designs. With highly customized dashboards and automated alarm notifications, Centaur can alert users before a critical asset experiences a failure or previously unforeseen event.

The benefits realized with Hydro’s Wireless Condition Monitoring Solution are:

  • Real-time data – not dependent on the next route cycle
  • High-frequency data collection – no more missed events or issues
  • Increased safety resources available for data analysis – reducing in-field data collection time increases availability for analysis
  • Customizable alerts and alarms give users the assurance to operate their machines without concern
  • Maintenance schedules can be optimized based on machine condition

For over 50 years, Hydro has been providing customers with creative engineering solutions to complex pump problems. Now, Hydro offers 360° support for customers’ rotating machinery with Centaur: Hydro’s Wireless Condition Monitoring Solution.

Do you have concerns regarding your critical asset reliability? Visit https://hydroinc.com/centaur or call 1-800-223-7867 to learn more about Hydro’s suite of services.

Hydro Australia Opens Pump Repair Service Centre in Darwin

Hydro Australia - Reverse Engineering & ROMER Arm

Hydro Australia provides a wide range of reverse engineering capabilities and services

Hydro Australia, a Hydro, Inc. company, opened its new pump repair service centre this April, in Darwin. The service centre is located at 23 Beresford Road, Yarrawonga NT 830.

Open from 7:00 AM – 3:30 PM, this service centre joins a team of worldwide pump refurbishment centres. At Hydro’s Darwin location, customers can rely on engineers to help with a wide range of pump challenges.

Do you want to minimize downtime? Do you need engineering consulting? Would you like your pumps to run more efficiently? If yes, Darwin’s service centre is ready to support you with any, and all, pump issues.

For more information, contact Darwin’s Service Centre, at +61 0419 551 911 or visit them online at, hydroaustralia.com.au.

 

Introducing: Hydro Australia from Hydro, Inc. on Vimeo.