ADVERTORIAL FEATURE | HYDRO INC.
Below left: The disassembled pump, prior to reverse engineering
Below right: Technician laser scanning the casing with a coordinate measuring machine
Reverse engineering a boric acid pump
Whether it is finding a solution for obsolescence or an existing supplier using the latest technology, a robust equivalency process will ensure a new pump component will meet fit, form and function, as Faisal Salman of Hydro Inc. explains
Hydro requested the pump be disassembled prior to arrival. All parts were documented against the bill of
material. We then performed: ● Visual inspection of all parts ● Logging of parts ● Collection of part numbers, BOMs, cross sectional drawings
● Dimensional characteristics, physical characteristics and obtained photographs
NUCLEAR PLANTS TODAY ARE BEING pushed to perform at optimum efficiency with the lowest cost. Reverse engineering can help achieve the goals. Partnering with the right supplier that has the experience and technical competency on reverse engineering can play an important role ensuring quality parts are supplied. At Hydro, we have been reverse engineering pump
Above:
Geometric deviation analysis, part of Hydro Equivalency Report
components for over 35+ years. In that time, we have developed processes to help ensure replacement components that meet the original design characteristics. We also provide an Equivalency Document which showcases the physical evidence that the final product is equivalent to the original components. Case in point is a boric acid pump at a nuclear plant in
Europe. This pump model was no longer being supported by the OEM and the station was pressed to find a solution to obsolete parts. It is important that solution was as simple as possible by providing a drop-in replacement. The plant was not interested in a new pump which would require modifications to piping, foundation, and baseplate. A drop-in replacement offered the end-user the lowest overall cost.
Our engineering team met with the end-user and
Above: 3D scans of the pump. Top: raw data from the scan. Bottom: data after analysis and conversion to models for casting by Hydro’s reverse engineering team
proposed reverse engineering the pump. After approval Hydro Engineering developed the plan for the reverse engineering team. Each component was evaluated, and special instructions were conveyed to the reverse
engineering team. The kickoff meeting discussed: ● Specific parts to be reverse engineered ● Required tooling at location ● Critical aspects of each component that require special attention
● Calibration being up-to-date on all measuring equipment
● Time requirements for overall project 38 | October 2021 |
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Collecting dimensional characteristics was achieved using both calibrated hand measuring tools, such as micrometers and Coordinate Measuring Machines (CMM). Our CMMs are portable measuring machines that use both probes and a laser scanner to capture all critical dimensional features of the parts we reverse engineer. We developed custom designed probes for our CMMs. These probes are special for the unique geometries found in impeller and casings. These probes obtain data where the laser cannot, due to obstructions to line of sight. Complex hydraulic castings are digitized into a 3D point cloud using the laser scanner. This enables our engineers to perform analysis and extract the key design features that can be used for engineering the replacement parts needed. 3D models are then generated. Hydro Engineering
review the 3D models and generate the final dimensions and tolerances. All tolerances have robust engineering justification and is provided to the client in our Equivalency Document. The proper QA requirements are reviewed, and the
components are then released for manufacturing. After manufacture and assembly, the pump is tested at the Hydro Test Lab and performance is verified. The final document is our Hydro Equivalency Document.
In this document, Hydro provides: ● Geometric verification of final part vs OEM part ● Material certification
Hydro performs a deviation analysis comparing the critical geometric points on the Hydro part versus the OEM part. We rescan an impeller or casing using our Laser CMM. Our deviation analysis highlights any geometric deviations from the original part. The OEM 3D model is overlaid with the Hydro 3D model, this critical step provides the verification that the components are geometrically equal. Hydro has supplied ten pumps total. All pumps are
operating at their original design point and the pump fit in its location perfectly. ■
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