Next generation boiler circulating pump solutions
for the global energy sector
Boiler circulation pump standardisation for 2-pole 50Hz (2960rpm) speed
225
10.5*420A
10*450A
8*10*16DIFF
7.5*381A
9.5*370A
7*366A
9.5*356A
8*356A
7.5x335A
11*335A
11.5*348A
200
10x450A
8x10x16A
175
7.5x381A
10.5x420A
Head m
150
7x366A
9.5x370A
Next generation of
performance-critical
boiler circulating pumps
for the power industry
8x356A
125
9.5x356A
7.5x355A
11.5x348A
100
11x355A
75
Performance-critical pumping solutions
for increased performance and lower
lifetime cost of ownership
50
25
0
500
1000
Quantity m³/h
1500
2500
2000
Motor
Power Ratings
Voltage
Frequency
VSD Compatible
Design Life
Motor Design
Speeds
300-2500kW
400V-11kV
50/60Hz operation
Yes
25+ years
2/4/6 pole designs
Up to 3,600rpm
For further information on Hayward Tyler’s next generation of performance-critical
boiler circulating pumps for supercritical and ultra-supercritical applications,
please contact us at a location shown below or visit www.haywardtyler.com/power
Engineered solutions for the global energy sector
Corporate Headquarters
Hayward Tyler
1 Kimpton Road
Luton LU1 3LD
England
China - Shanghai
Hayward Tyler
Shanghai Hi-tech King Worldzone
East Building
#688 East Beijing road
24th Floor, Room E1
Shanghai, China
China - Kunshan
Hayward Tyler 1st Factory
No. 243
Huang Pujiang Middle Road
Kunshan
Jiangsu Province
China 215300
India
Hayward Tyler 509–510 Charmwood Plaza
EROS Garden
Surajkund Road
Faridabad 121009
Haryana
India
USA
Hayward Tyler
PO Box 680
480 Roosevelt Highway
Colchester
Vermont 05446
USA
Tel: +44 (0)1582 731144
Fax: +44 (0)1582 452198
Email: luton@haywardtyler.com
Tel: +86 (21) 5101 2876
Fax: +86 (512) 5772 3322
Email: kunshan@haywardtyler.com
Tel: +86 (512) 5772 3311
Fax: +86 (512) 5772 3322
Email: kunshan@haywardtyler.com
Tel: +91 129 251 3579/251 0124
Fax: +91 129 251 3035
Email: delhi@haywardtyler.com
Tel: +1 (802) 655 4444
Fax: +1 (802) 655 4682
Email: vermont@haywardtyler.com
Hayward Tyler designs, manufactures
and services fluid-filled electric motors
and pumps for performance-critical
applications across the power market.
With more BCPs installed worldwide
than any other manufacturer, we
are the industry’s first choice for
performance and reliability.
g
60 years’ experience
g
Designed world’s first glandless BCP
g
Largest installed base
– 2,300 BCP units worldwide
g
11kV high voltage design
g
Sub, super and ultra-supercritical capability
g
30+ years’ design lifetime
g
40-week standard lead time
g
24/7/365 customer service
OUR BCP MOTORS
OPERATE FOR UP TO
65,000 HOURS
BETWEEN MAINTENANCE
Faced with today’s tough market challenges,
you can’t afford to take any risks – you must
know who you can always rely on to deliver
to specification, on time, and on budget.
Global reputation
Continuous improvement
For the past 200 years, Hayward Tyler has been meeting
– and exceeding – client expectations and we have built
a global reputation for industry-leading innovation, quality,
and reliability.
We understand that you can never achieve reliability
without quality, and we have an over-arching commitment
to continuous improvement.
Hayward Tyler is recognised worldwide as a leading
manufacturer of glandless wet stator circulating pumps
for the power industry.
We invented the technology over 60 years ago and now
have more than 2,300 units operating in both nuclear
and conventional fossil-fuelled power generating plants.
These include GT combined cycle, fluidised bed, and
coal gasification installations.
Our market leadership is underpinned by our commitment
to continuous technical improvement, product quality
and reliability.
Trusted partner
Our circulation pumps are a tried and tested solution
for performance-critical, high pressure, high temperature
boiler systems. We are a preferred supplier to major EPCs
and boiler manufacturers worldwide who recognise us for
our unsurpassed experience and engineering know-how.
We are the ‘go-to’ trusted partner for tough challenges,
and we work with operators and EPCs to develop the
next generation circulation pump technology needed
to operate at the high pressures and temperatures
demanded by state-of-the-art super and
ultra-supercritical boiler systems.
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Our exceptional workforce, our state-of-the-art production
line, and our fully flexible supply chain allows us to deliver
the most complex projects anywhere in the world against
an average 40-week lead-time and with an assured
65,000 hours Mean Time Between Maintenance (MTBM).
Centre of Excellence
We are creating the world’s most advanced Centre of
Excellence for specialist fluid-filled motor manufacture,
a cutting edge facility where our enhanced test capability
and lean manufacturing processes will enable our next
generation technology to be delivered with unrivalled
quality assurance and even shorter lead times.
OUR BUSINESS-WIDE CONTINUOUS IMPROVEMENT
PROCESSES ARE FURTHER ENHANCING OUR
COMMITMENT TO PERFORMANCE, RELIABILITY,
SERVICE LIFE, AND EASE OF MAINTENANCE.
CASE STUDY:
Leading the way in large-scale
coastal power generations
China’s Zhejiang Ninghai Power Plant is breaking
new ground in large-scale coastal power generation
and is the first of its kind to use a desalinated
seawater circulation cooling system so eliminating
any environmental impact on adjacent sea areas
caused by warm water discharge.
The operators chose Hayward Tyler glandless
wet stator boiler recirculation pumps for both the
Zhejiang Ninghai Phase II 1,000MW super-critical
once-through boilers, and the project has won a
gold medal in China’s prestigious National Quality
Project Award as well as the Year 2010-2011
Luban Award.
Our BCPs are used by the world’s
leading operators including:
g
APGENCO
g
China Guodian Corporation Co.
g
China Huadian Group
g
China Huaneng Group
g
China Shenhua Energy Co.
g
CLP
g
Datang International Power
Generation Co.
g
Duke Energy
g
DVC
g
ENEA (Poland)
g
EON
g
Eskom
g
HPGCL
g
MAHAGENCO
g
NTPC
g
Tata Power
5
370bar
@ 3800C
Performance-critical pumps for the toughest
power generation environments.
You must be able to rely 100% on the technology
that drives your operations, and with Hayward
Tyler you can be confident you’re in safe hands.
Our high-availability, low-maintenance glandless
motor and pump units are recognised worldwide
as the most reliable and robust available today.
Global service capability
Our status as an industry-leading OEM supplier is reflected
in our commitment to world-class after-sales service.
We have dedicated facilities in the UK, USA, India, and China
with our specialist field personnel delivering the full range
of service and repair options for all planned and predictive
maintenance cycles as well as a comprehensive electrical
and mechanical inspection capability.
HIGH RELIABILITY
(30+ YEARS DESIGN
LIFETIME)
LONGER SERVICE
INTERVALS
(PROVEN 8 YEARS)
SUB, SUPER AND
ULTRA-SUPERCRITICAL
CAPABILITY
LOWER TOTAL COST
OF OWNERSHIP
CASE STUDY:
CASE STUDY:
Supercritical support for coal-fired
power station
Meeting mega project start-up
cycle challenge
An additional €1.3 billion coal-fired supercritical unit with
an installed capacity of 1,000MW has recently been built
at Poland’s second largest power station, Kozienice, which
is owned by Elektrownia Wytwarzanie S.A. and has a total
capacity of 2,820MW.
The Barh II supercritical boiler project is recognised as a mega
project within the Indian power sector, enhancing capacity at
the site near Patna from 11,558MW to 17,333MW.
Main contractor Mitsubishi Hitachi Power Systems Europe
GmbH selected a Hayward Tyler BCP to act as a vital
component during boiler start-up cycles.
The pump has been designed and manufactured in
strict compliance with EN Codes and Standards.
Main contractor Alstom Power USA selected Hayward Tyler
boiler circulation pumps for this National Thermal Power
Corporation project, and they now form a vital component
during boiler start-up cycles.
Designed in accordance with Indian Boiler Regulations (IBR)
and ASME pressure vessel codes, the pumps were – as part of
pre-delivery testing – subjected to a highly demanding obligatory
NTPC hot test. For this, a purpose-built test loop was configured
to replicate the pressures and temperatures to which the pumps
would be exposed during installed operation.
Our after-sales support can be delivered on a supervised
or turnkey basis, with turnkey now growing in popularity
as an effective means of reducing staffing overheads.
All Hayward Tyler service centres also offer design updates,
troubleshooting and root cause failure analysis, with our
engineering field support teams available to work with you
on-site.
We hold all the original parts and service drawings not only
of our own original products but also for GE-manufactured
BCPs, and we also provide field and shop service capabilities
for GE, Westinghouse, KSB, IR, Fuji and Torishima BCPs.
Our service centres can supply identical part-for-part spares
or our teams can take advantage of design upgrades and
improvements and deliver smaller, lighter replacement products.
Many clients opt to invest in spare motors designed to the
original’s specification which we can store at one of our facilities
and that can be routinely overhauled during non-premium time.
This allows rapid swap-out when the main motor is out of
action, so reducing maintenance costs and significantly
cutting outage times.
Quality and durability
Our commitment to continuous improvement means all our
products are durable and meet – or exceed – quality standards.
A key reason for our worldwide recognition as the leading
supplier of glandless motor pumps is the simplicity of pressure
containment within our design, which comprises three
continuously connected vessels:
Pump case – accommodates fluids to the highest
boiler temperatures and pressures.
Motor case – maintained at low temperatures but
with full system pressure.
Simplicity is a key feature of the
Hayward Tyler BCP, with both pump
and casings designed for the full range
of boiler pressures and temperatures
All our products meet standards set
by ASME, PED, IBR, EN and ISO.
Quality Standards:
ASME, PED, IBR
EN, and ISO
Heat exchanger – sized to maintain the motor cavity
coolant at low temperatures while at full system pressure.
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High power, high performance,
low maintenance.
2,300
40 WEEK
65,000
200
UNITS
- LARGEST GLOBAL
INSTALLED BASE
AVERAGE LEAD-TIME IN
DELIVERING COMPLEX
PROJECTS
HOURS MEANTIME
BETWEEN
MAINTENANCE
YEAR HERITAGE IN DESIGN,
ENGINEERING AND
PRODUCTION
Simplicity of design, unrivalled manufacturing
numbers and operational experience all make
Hayward Tyler the boiler and utility sector’s
preferred choice.
Our products incorporate an array of industry
leading features to help drive efficiency, ensure
reliability and deliver low maintenance, a long
lifespan, and a high ROI – however challenging
the operating environment.
Seal-less canned motor pumps
By eliminating the need for shaft seals and oil-lubricated
ball bearings, we greatly improve the Mean Time Between
Failure (MTBF) through designing out the two most common
pump failure components.
Instead, we rely on a proven process lubrication bearing
design, and also integrate the motor and wet end of our
canned pumps, removing the need for a coupling, guard
or heavy-duty baseplate and so reducing installation costs.
Glandless retrofit motors
We can retrofit our glandless technology to your existing
pump cases and impellers, replacing the entire seal system
and motor assembly with a unit capable of running for years
without maintenance.
Based on continuous operation, overhauls are typically at
five or six-year intervals, and we can retrofit regardless of
pump case orientation, from 30kW to 3,000kW, two-pole,
four-pole or even six-pole, and up to 415 Bar g pressure.
Ultra-supercritical, supercritical,
subcritical capabilities
OPTIONS:
Unit arrangement
Pumps
g
Cast or forged pump case
g
Single or double discharge
Our glandless pumps are arranged vertically, with
the motor usually suspended below the pump case
which is welded to the boiler suction and discharge
pipework. The unit does not need foundation bolts
and can therefore move as the boiler pipework
expands and contracts.
We can also install above the pump when
retrofitting glandless wet stator motors to
existing units, and this is particularly
useful where there are problems with
mechanical seal pumps driven by
conventional air-cooled motors.
Motor stator
Our motor stator windings comprise copper cores
covered in an XLPE insulation, with a PVC sleeve
delivering additional protection. The stator is easily
removed from the casing for repair.
Motors
g
Any voltage up to 11kV
g
Fluid-filled wet stator or canned dry ‘seal-less’ motors
KEY FEATURES:
Hot neck
The unique hot neck arrangement,
which is part of the motor case forging,
limits the transfer of heat from the
pump to the motor and negates the
need for a separate heat barrier with
independent cooling water supply.
g
High-pressure units
g
Tilting pad bearings
g
Removable stator cartridge
g
Single external cooling water supply
g
No external filters
g
Common pump/motor shaft removes alignment issues
APPLICATIONS:
Hayward Tyler offer pump solutions for:
g
Ultra-supercritical boiler start-up
g
Subcritical boiler circulation
g
Drum boiler circulation
g
Fluidised bed boiler circulation
g
Economiser re-circulation
g
Nuclear auxiliary and safety systems
g
Reactor primary circulation
g
Retrofit motors for existing conventional pumps
We use PVC wedges to secure the windings in
the stator slots, and the ends turns are bound
together and tied to supports on the stator shell
to minimise movement.
Moulded jointing system
Our proprietary injection moulded jointing
system has been approved by an independent
industry body which subjects the joints to
accelerated lifetime testing.
The process ensures that the high-integrity
internal joints meet the exacting standards
needed for high-duty applications and deliver
long-life performance.
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Tilting pad design
All Hayward Tyler pump and cover end motor
radial bearings are high-capacity, asbestosfree and of the tilting pad design. They are
exceptionally tolerant to magnetite ingress
from boilers, and the pump end radial
bearing is positioned to minimise impeller
overhang while limiting temperature rise.
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Staying in front as the power
sector’s top choice.
Into the future with our
Centre of Excellence.
We are always striving to maintain and grow our
position as the power generation industry’s first
choice for performance-critical motors and pumps,
and we are achieving this through an ambitious
programme of continuous improvement.
Our multi-million pound investment in the new
Hayward Tyler Centre of Excellence adds further
facilities to our already extensive HQ in Luton
as well as significant extra support for R&D and
the training and development of our workforce.
Across our facilities in the UK, USA, China and India, we are
putting in place a strategy that focuses fully on our company-wide
‘people, products, processes’ philosophy and links back to our
200-year heritage.
Hayward Tyler already leads the way in innovative design,
engineering and production process across the energy sector
– not just in power generation, but also in upstream oil and gas
and renewables – and we are committed to further enhancing
the products and services we can offer.
A cornerstone is the development of our ground-breaking
Centre of Excellence at our headquarters in the UK, a facility
perfectly suited to our ambition to continue to remain at
the forefront of design, engineering and production in
the 21st century.
Our expert knowledge,
precision engineering and
world-class manufacturing
processes enable us to deliver
unsurpassed product capabilities,
reliability and performance.
Ewan Lloyd-Baker, Chief Executive,
Hayward Tyler Group plc
For our clients, this means reduced lead times, even better
certainty of supply, reliable project delivery, and top-level
engineering support and analysis.
As part of this customer-centric quest for continuous improvement,
we have achieved a Civil Nuclear Sharing in Growth award that
is allowing us to up-skill our UK workforce to meet ‘Fit For Nuclear’
standards and this achievement will carry across into all that
we do.
Our manufacturing centre is already certified to ISO 9001 and
has been granted both ASME and nuclear accreditation, and
we are the only UK provider of industry-specific hotbed testing.
People
Products
Processes
Our people are the very heart of everything
we do. We have a highly skilled global
workforce passionate about our business,
and we have created the right workplace
environment for them to grow. As part
of our ongoing commitment to their
development, we have rolled out lean
foundation training for all staff and offer
universal access to both in-house and
external learning opportunities, including
MBAs for our senior managers.
We have a reputation for reliability and
the long-term durability of our fluid-filled
motors and pumps and their ability to
perform in complex applications and
challenging environments. All our products
and services are designed to give our
customers a competitive advantage and
enhanced ROI through excellent lifetime
cost of ownership. We invest heavily in
world-class research and innovation to
ensure our offer remains the best available.
Reduced lead times, superior test
capability, lean manufacturing and Six
Sigma methodologies delivered from our
Centre of Excellence all contribute to giving
our customers exceptional peace of mind
and confidence. We constantly drive
operating efficiencies – both internally and
in supply chain partnerships – to generate
enhanced quality assurance, and our
continuous improvement programme is
fully focused on eliminating sub-optimal
processes across our business.
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