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NuclearPlantJournal.com Nuclear Plant Journal, September-October 2015
relative to the BOM (Bill of Material)
received.
In most cases, the bill of material
supplied identifies the material of the
components in the BOM, but in the
event there is no BOM, HydroAire
will utilize a material analyzer as well
as material analysis by a third party
material laboratory to positively identify
materials. In these cases the material lab
will analyze material composition and
perform mechanical property tests for the
sample piece.
Following this exercise, we will
inspect each component and start
the process of geometric replication.
HydroAire uses many tools to perform
this critical task. Calibrated micrometers
and coordinate measuring machines are
the key hardware pieces which insure
accuracy. The technician controlling
these tools has been specially trained
through HydroAire’s unique Process
Control Procedures (PCP) for Reverse
Engineering. Our PCP process has been
developed from 30 years of reverse
engineering of pump components. The
PCP insures the same detailed process
is adhered to time and time again. As
an example, our PCP requires a double-
check from a second technician to
review the measurements and BOM
reconciliation. Furthermore, a senior
pump design engineer will review the
measurements for all the components and
determine the final sizes and tolerances.
Following engineering’s approval,
the final design drawing for each
component is generated detailing all key
design attributes.
Once HydroAire manufactures the
new pump , HydroAire will perform a full
pump performance test in our dedicated
test facility insuring the hydraulic
performance is identical to the original
and that the pump is mechanically sound
and ready to provide reliable operation.
A new BOM is generated with
HydroAire part numbers. We submit
the new BOM to the customer with
equivalency documents for each part and
relevant general drawings.
3.
Does HydroAire provide any service
for doing “physical checkups” of
pumps and motors, including preventive
maintenance, during refueling outage?
HydroAire has a division that
specializes in onsite pump health to
analyze the performance and condition of
operating pumps. HydroAire uses state-
of-the-art equipment to perform these
tasks.
We can support routine condition
monitoring as well as sophisticated
vibration analysis to check for resonant
frequency and critical frequency, using
operating deflection shape (ODS).
As this relates to reliability services,
our service offering would be prior to
refueling outage (before the unit goes
down) and possibly afterwards, so that
we can collect test data and determine a
proactive game plan which may include
physical maintenance work (either
predictive or routine maintenance) being
done during the actual outage.
A typical hydraulic and mechanical
test includes:
Vibration analysis (including phase
data)
Flow measurement
Pressure measurement
Bus voltage and motor current data
collection
Motor current analysis (if needed)
Speed measurement
Maintenance and operations record
review
This test data allows us to perform
a full electro-mechanical evaluation on
the motor, and also a full hydraulic and
mechanical evaluation of the pump.
Additionally, we will evaluate the
condition of the seal and lube oil during
the testing, thus allowing us to provide
a “game plan” for either predictive
maintenance, correction actions for on-
going conditions or potential hydraulic or
mechanical upgrades.
Report for nuclear work will require
two weeks for one pumping system.
4.
What are the most challenging repair
and testing jobs undertaken by HydroAire
in the last two years?
HydroAire specializes in unique
repair challenges under emergency
conditions.An example of a contaminated
safety related pump is given below.
The nuclear plant was in a seven day
LCO (Limiting Condition for Operation).
Our mission was to decontaminate,
inspect and repair a low head safety
injection pump with new parts and weld
repair the case. Following this, it was
required to performance test the pump
with all work being completed in less
than seven days.
Furthermore, the client supplied a
new OEM impeller with no hydraulic
or material traceability. Since there
was no time to test the impeller as
found, HydroAire had to perform a
numerical method analysis predicting the
performance with no room for error. A
further problem occurred when the OEM
parts did not fit correctly upon assembly.
HydroAire had to execute engineering
and rework to insure proper functionality.
The two issues involved were upon
installation of the OEM impeller, the
casing would not close. HydroAire had
to ascertain the geometric discrepancy,
correct it and then test the unit. The
second issue was with the mechanical
seal.
A second, but notable project was
when a nuclear plant installed a Stator
cooling pump. During an outage the
plant removed a new spare pump from
inventory and upon installation it was
discovered that flanges on the pump
and piping didn’t line up and nor did
the pedestal bolts. This occurred despite
the unit having been bought from the
OEM as an exact duplicate to the pump
being replaced. Additionally, two further
casings in inventory didn’t line up with
the original either. The installation of
these pumps was critical to end of the
outage and startup of the plant.
HydroAire was called for assistance
in remedying the situation. The approach
taken was to laser scan the entire area
where these pumps were installed in the
plant as well as the existing spare casings
and then perform all modifications
necessary within a two week envelope.
HydroAire also tested the pump at our
test facility to ensure operability.
This project required immediate
mobilization of tooling and engineers to
work together and perform the detailed
analysis and modification within a seven
day time frame.
5.
What innovative technologies are
utilized in pump and motor repair?
The first one is utilizing 3D printing
technology for casting reproduction. This
Meeting the...
