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

Next generation of
10*450A
200 8*10*16DIFF
10x450A 7.5*381A
8x10x16A 9.5*370A
175 7*366A

performance-critical
7.5x381A 9.5*356A
8*356A
10.5x420A 7.5x335A
150
7x366A 11*335A
9.5x370A
11.5*348A

boiler circulating pumps

8x356A
125
Head m

9.5x356A
7.5x355A
11.5x348A

for the power industry

100
11x355A

75

50
Performance-critical pumping solutions
25
for increased performance and lower
lifetime cost of ownership
0
500 1000 1500 2000 2500
Quantity m³/h

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 China - Shanghai China - Kunshan India USA
Hayward Tyler Hayward Tyler Hayward Tyler  Hayward Tyler  Hayward Tyler
1 Kimpton Road Shanghai Hi-tech King Worldzone 1st Factory 509–510 Charmwood Plaza PO Box 680
Luton LU1 3LD East Building No. 243 EROS Garden 480 Roosevelt Highway
England #688 East Beijing road Huang Pujiang Middle Road Surajkund Road Colchester
24th Floor, Room E1 Kunshan Faridabad 121009 Vermont 05446
Shanghai, China Jiangsu Province Haryana USA
China 215300 India
Tel: +44 (0)1582 731144 Tel: +86 (21) 5101 2876 Tel: +86 (512) 5772 3311 Tel: +91 129 251 3579/251 0124 Tel: +1 (802) 655 4444
Fax: +44 (0)1582 452198 Fax: +86 (512) 5772 3322 Fax: +86 (512) 5772 3322 Fax: +91 129 251 3035 Fax: +1 (802) 655 4682
Email: luton@haywardtyler.com Email: kunshan@haywardtyler.com Email: kunshan@haywardtyler.com Email: delhi@haywardtyler.com Email: vermont@haywardtyler.com
Hayward Tyler designs, manufactures 60 years’ experience
g
Designed world’s first glandless BCP
g
and services fluid-filled electric motors Largest installed base
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and pumps for performance-critical – 2,300 BCP units worldwide
11kV high voltage design
g
applications across the power market. Sub, super and ultra-supercritical capability
g

With more BCPs installed worldwide 30+ years’ design lifetime

g
40-week standard lead time
g
than any other manufacturer, we 24/7/365 customer service
g
are the industry’s first choice for
performance and reliability.

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
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.
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.
4 5
OUR BUSINESS-WIDE CONTINUOUS IMPROVEMENT CASE STUDY:
PROCESSES ARE FURTHER ENHANCING OUR
COMMITMENT TO PERFORMANCE, RELIABILITY, Leading the way in large-scale
SERVICE LIFE, AND EASE OF MAINTENANCE. 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
Continuous improvement wet stator boiler recirculation pumps for both the
Zhejiang Ninghai Phase II 1,000MW super-critical
We understand that you can never achieve reliability once-through boilers, and the project has won a
without quality, and we have an over-arching commitment gold medal in China’s prestigious National Quality
Project Award as well as the Year 2010-2011
to continuous improvement.
Luban Award.
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).
Our BCPs are used by the world’s
leading operators including:
Centre of Excellence g APGENCO
We are creating the world’s most advanced Centre of g China Guodian Corporation Co.
Excellence for specialist fluid-filled motor manufacture, g China Huadian Group
a cutting edge facility where our enhanced test capability g China Huaneng Group
and lean manufacturing processes will enable our next g China Shenhua Energy Co.
generation technology to be delivered with unrivalled g CLP
quality assurance and even shorter lead times. 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

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.
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.
6 7
370bar
@ 3800C
HIGH RELIABILITY LONGER SERVICE SUB, SUPER AND LOWER TOTAL COST
(30+ YEARS DESIGN INTERVALS ULTRA-SUPERCRITICAL OF OWNERSHIP
LIFETIME) (PROVEN 8 YEARS) CAPABILITY
CASE STUDY: CASE STUDY:
Supercritical support for coal-fired Meeting mega project start-up
power station cycle challenge
An additional €1.3 billion coal-fired supercritical unit with The Barh II supercritical boiler project is recognised as a mega
an installed capacity of 1,000MW has recently been built project within the Indian power sector, enhancing capacity at
at Poland’s second largest power station, Kozienice, which the site near Patna from 11,558MW to 17,333MW.
is owned by Elektrownia Wytwarzanie S.A. and has a total Main contractor Alstom Power USA selected Hayward Tyler
capacity of 2,820MW. boiler circulation pumps for this National Thermal Power
Main contractor Mitsubishi Hitachi Power Systems Europe Corporation project, and they now form a vital component
GmbH selected a Hayward Tyler BCP to act as a vital during boiler start-up cycles.
component during boiler start-up cycles. Designed in accordance with Indian Boiler Regulations (IBR)
The pump has been designed and manufactured in and ASME pressure vessel codes, the pumps were – as part of
strict compliance with EN Codes and Standards. 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.
Quality and durability
Our commitment to continuous improvement means all our
products are durable and meet – or exceed – quality standards.
Simplicity is a key feature of the
A key reason for our worldwide recognition as the leading
Hayward Tyler BCP, with both pump
supplier of glandless motor pumps is the simplicity of pressure
and casings designed for the full range
containment within our design, which comprises three
of boiler pressures and temperatures
continuously connected vessels: All our products meet standards set
Pump case – accommodates fluids to the highest by ASME, PED, IBR, EN and ISO. Quality Standards:
boiler temperatures and pressures. ASME, PED, IBR
EN, and ISO
Motor case – maintained at low temperatures but
with full system pressure.
Heat exchanger – sized to maintain the motor cavity
coolant at low temperatures while at full system pressure.
 2,300 40 WEEK 65,000 200
UNITS AVERAGE LEAD-TIME IN HOURS MEANTIME YEAR HERITAGE IN DESIGN,
- LARGEST GLOBAL DELIVERING COMPLEX BETWEEN ENGINEERING AND
INSTALLED BASE PROJECTS MAINTENANCE PRODUCTION

High power, high performance,

low maintenance.
Simplicity of design, unrivalled manufacturing
numbers and operational experience all make Ultra-supercritical, supercritical,
Hayward Tyler the boiler and utility sector’s subcritical capabilities
preferred choice.
OPTIONS:
Our products incorporate an array of industry Unit arrangement Pumps
leading features to help drive efficiency, ensure Our glandless pumps are arranged vertically, with g Cast or forged pump case
reliability and deliver low maintenance, a long the motor usually suspended below the pump case g Single or double discharge
lifespan, and a high ROI – however challenging which is welded to the boiler suction and discharge
Motors
pipework. The unit does not need foundation bolts
the operating environment. and can therefore move as the boiler pipework
g Any voltage up to 11kV
expands and contracts. g Fluid-filled wet stator or canned dry ‘seal-less’ motors

Seal-less canned motor pumps We can also install above the pump when
KEY FEATURES:
retrofitting glandless wet stator motors to
By eliminating the need for shaft seals and oil-lubricated existing units, and this is particularly
ball bearings, we greatly improve the Mean Time Between High-pressure units
g
useful where there are problems with
Failure (MTBF) through designing out the two most common Tilting pad bearings
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mechanical seal pumps driven by
pump failure components. conventional air-cooled motors. Removable stator cartridge
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Hot neck Single external cooling water supply
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Instead, we rely on a proven process lubrication bearing
The unique hot neck arrangement, No external filters
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design, and also integrate the motor and wet end of our
which is part of the motor case forging, Common pump/motor shaft removes alignment issues
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canned pumps, removing the need for a coupling, guard Motor stator limits the transfer of heat from the
or heavy-duty baseplate and so reducing installation costs.
Our motor stator windings comprise copper cores pump to the motor and negates the APPLICATIONS:
covered in an XLPE insulation, with a PVC sleeve need for a separate heat barrier with
Glandless retrofit motors delivering additional protection. The stator is easily independent cooling water supply. Hayward Tyler offer pump solutions for:
We can retrofit our glandless technology to your existing removed from the casing for repair. Ultra-supercritical boiler start-up
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pump cases and impellers, replacing the entire seal system We use PVC wedges to secure the windings in Subcritical boiler circulation
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and motor assembly with a unit capable of running for years the stator slots, and the ends turns are bound Drum boiler circulation
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without maintenance. together and tied to supports on the stator shell Fluidised bed boiler circulation
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to minimise movement.
Based on continuous operation, overhauls are typically at Economiser re-circulation
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five or six-year intervals, and we can retrofit regardless of Nuclear auxiliary and safety systems
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pump case orientation, from 30kW to 3,000kW, two-pole, Reactor primary circulation
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four-pole or even six-pole, and up to 415 Bar g pressure. Retrofit motors for existing conventional pumps
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Moulded jointing system

Our proprietary injection moulded jointing
system has been approved by an independent Tilting pad design
industry body which subjects the joints to
accelerated lifetime testing. All Hayward Tyler pump and cover end motor
radial bearings are high-capacity, asbestos-
The process ensures that the high-integrity
free and of the tilting pad design. They are
internal joints meet the exacting standards
exceptionally tolerant to magnetite ingress
needed for high-duty applications and deliver
from boilers, and the pump end radial
long-life performance.
bearing is positioned to minimise impeller
overhang while limiting temperature rise.

8 9
Staying in front as the power Into the future with our
sector’s top choice. Centre of Excellence.
We are always striving to maintain and grow our Our multi-million pound investment in the new Our expert knowledge,
position as the power generation industry’s first Hayward Tyler Centre of Excellence adds further precision engineering and
choice for performance-critical motors and pumps, facilities to our already extensive HQ in Luton world-class manufacturing
and we are achieving this through an ambitious as well as significant extra support for R&D and processes enable us to deliver
programme of continuous improvement. the training and development of our workforce. unsurpassed product capabilities,
Across our facilities in the UK, USA, China and India, we are Hayward Tyler already leads the way in innovative design, reliability and performance.
putting in place a strategy that focuses fully on our company-wide engineering and production process across the energy sector
‘people, products, processes’ philosophy and links back to our – not just in power generation, but also in upstream oil and gas Ewan Lloyd-Baker, Chief Executive,
Hayward Tyler Group plc
200-year heritage. and renewables – and we are committed to further enhancing
A cornerstone is the development of our ground-breaking the products and services we can offer.
Centre of Excellence at our headquarters in the UK, a facility For our clients, this means reduced lead times, even better
perfectly suited to our ambition to continue to remain at certainty of supply, reliable project delivery, and top-level
the forefront of design, engineering and production in engineering support and analysis.
the 21st century.
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.

10 11