Next generation of

performance-critical
boiler circulating
pumps for the
power industry
Industry’s first choice for reliability,
increased performance, and lower
lifetime cost of ownership
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 reliability,
increased performance and lower
lifetime cost of ownership.
 60 years’ experience
g
Designed world’s first glandless BCP
g
Largest installed base
g
- 2,300 BCP units worldwide
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
g

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.
For over 200 years, Hayward Tyler has been Quality and reliability
meeting and exceeding client expectations. We understand that you can never achieve reliability
We have built a global reputation for industry- without quality, and we have an over-arching commitment
to continuous improvement.
leading innovation, quality, and reliability.
Our exceptional workforce, our state-of-the-art production line,
Global reputation and our fully flexible supply chain allows us to deliver the most
complex projects anywhere in the world against an average
Hayward Tyler is recognised worldwide as a leading
40-week lead-time and with an assured 65,000 hours Mean
manufacturer of glandless wet stator circulating pumps for
Time Between Maintenance (MTBM).
the power industry.
We invented the technology over 60 years ago and now
have more than 2,300 units operating in both nuclear and
Centre of Excellence
conventional fossil-fuelled power generating plants. These We have created the world’s most advanced Centre of
include GT combined cycle, fluidised bed, and coal Excellence for specialist motor manufacture, a cutting-edge
gasification installations. facility where our enhanced test capability and lean manufacturing
processes will enable our next generation technology to be
Our market leadership is underpinned by our commitment delivered with unrivalled quality assurance and even shorter
to continuous technical improvement, product quality and lead times.
reliability.
Central to the Centre of Excellence is the continued development
of our Marketing, Sales & Operational Planning (M,S&OP)
Proven where performance is critical award winning information systems. A business differentiator
Our circulation pumps are a tried and tested solution for which is recognised by our peers in the UK.
performance-critical, high pressure, high temperature boiler
We have embedded “What-if” scenario planning capability
systems. We are a preferred supplier to major EPCs and
through highly customised Witness Simulation software. This
boiler manufacturers worldwide who recognise us for our
benefits our strategic partners throughout the entire supply
unsurpassed experience and engineering know-how.
chain using predictive simulation technology proven to maximise
performance, optimise throughput and resource utilisation.
Trusted partner
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
 OUR BUSINESS-WIDE CONTINUOUS IMPROVEMENT CASE STUDY:
PROCESSES ARE FURTHER ENHANCING OUR
Leading the way in large-scale
COMMITMENT TO PERFORMANCE, RELIABILITY,
coastal power generations
SERVICE LIFE, AND EASE OF MAINTENANCE.
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 chosen 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 East Delta
g ENEA (Poland)
g EON
g EGAT
g Eskom
g HPGCL
g MAHAGENCO
g NTPC
g PGESCO
g Tata Power

5
 Performance-critical pumps for the toughest
power generation environments.
You must be able to rely 100% on the
technology that drives your operations, and CASE STUDY:
with Hayward Tyler you can be confident Ultra-supercritical support for first
you’re in safe hands. lignite-fired power plant in Asia
Our high-availability, low-maintenance Hayward Tyler supplied a BCP for use as an efficient start-up
pump on the Mae Moh power plant - the first lignite-fired power
glandless motor and pump units are recognised
plant in Asia operating with ultra-supercritical conditions.
worldwide as the most reliable and robust The electric wet wound motor, which provides the drive to
available today. the pump, is 2-pole 400Kw operating off 11Kv voltage.
The ultra-supercritical boiler has an integrated Selective
Global service capability Catalytic Reduction of NOx (SCR), its ultra-supercritical steam
turbine and generator, as well as the air quality control systems
Our status as an industry-leading OEM supplier is reflected composed of a Wet Flue Gas Desulphurisation (WFGD) system.
in our commitment to world-class after-sales service. It will enable reduction of sulphur oxides by more than 98%, and
We have dedicated facilities in the UK, USA, India, and Electrostatic Precipitators (ESP), designed to capture particulate
China delivering though-life support. Our specialist field and dust emissions, with an efficiency of more than 99.9%.
personnel provide 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
Simplicity is a key feature of the
Torishima BCPs.
Hayward Tyler BCP, with both pump
Our service centres can supply identical part-for-part spares and casings designed for the full range
or our teams can take advantage of design upgrades and of boiler pressures and temperatures.
improvements and deliver smaller, lighter replacement All our products meet standards set
products. by ASME, PED, IBR, EN and ISO. Quality Standards:
Many clients opt to invest in spare motors designed to the ASME, PED, IBR
original’s specification, which we can store at one of our EN, and ISO
facilities and that can be routinely overhauled during non-
premium time. This allows rapid swap-out when the main
motor is out of action, reducing maintenance costs and
significantly cutting outage times.

6
 400bar
@ 4000C

HIGH RELIABILITY LONGER SERVICE SUB, SUPER AND LOWER TOTAL COST
(30+ YEARS DESIGN INTERVALS ULTRA-SUPERCRITICAL OF OWNERSHIP
LIFETIME) (PROVEN 8 YEARS) CAPABILITY

Quality and durability

Our commitment to continuous improvement means all our CASE STUDY:
products are durable and meet - or exceed - quality standards. Increasing power capacity at South Helwan
A key reason for our worldwide recognition as the leading power plant in Egypt
supplier of glandless motor pumps is the simplicity of pressure
containment within our design, which comprises three Hayward Tyler supplied three BCPs for use as start-up pumps
continuously connected vessels. to increase efficiency on the South Helwan supercritical power
plant in Egypt. The electric wet wound motors providing the
drive to the pump are 2-pole 500Kw motors operating off
6Kv voltage.
The plant comprises three identical units, each of 650 MW
gross capacities. The plant will be cooled by a once-through
Pump case cooling system using water from the Nile River.
Accommodates
fluids to the highest
boiler temperatures
and pressures.

Heat exchanger
Sized to maintain the motor cavity
coolant at low temperatures while
at full system pressure.

Motor case
Provides pressure tight housing
for the stator and rotor assemblies
whilst allowing circulation of the
cooling and lubricating medium.

7
 High power, high performance,
low maintenance.
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 Unit arrangement
leading features to help drive efficiency, ensure Our glandless pumps are arranged vertically, with
reliability and deliver low maintenance, a long the motor usually suspended below the pump case
lifespan, and a high ROI - however challenging which is welded to the boiler suction and discharge
pipework. The unit does not need foundation bolts
the operating environment. and can therefore move as the boiler pipework
expands and contracts.
Seal-less canned motor pumps We can also install above the pump when
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
useful where there are problems with
Failure (MTBF) through designing out the two most common
mechanical seal pumps driven by
pump failure components. conventional air-cooled motors.
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. Motor stator
Our motor stator windings comprise copper cores
covered in an XLPE insulation, with a PVC sleeve
Glandless retrofit motors delivering additional protection. The stator is easily
If you have issues with your existing fan cooled motor driven removed from the casing for repair.
mechanical seal pumps - such as excessive noise or leakage We use PVC wedges to secure the windings in
- these can be solved with a Hayward Tyler glandless wet the stator slots, and the ends turns are bound
stator motor. together and tied to supports on the stator shell
to minimise movement.
g Two-pole (2950 rpm) or 4 pole (1450 rpm) based
on 50HZ frequency
g Two-pole (3500 rpm) or 4 pole (1750 rpm) based
on 60HZ frequency
g Design parameters to meet supercritical boilers
400 Deg C / 400 Bar g pressure

The motors can be easily retrofitted to your boiler system using Moulded jointing system
the existing pump case and impeller to provide a leak free, Our proprietary injection moulded jointing
quiet pumping solution capable of running for many years system has been approved by an independent
maintenance free. Based on continuous operation, overhauls industry body which subjects the joints to
are typically at five or six-year intervals, and we can retrofit accelerated lifetime testing.
regardless of pump case orientation. The process ensures that the high-integrity
internal joints meet the exacting standards
needed for high-duty applications and deliver
long-life performance.

8
 2,300 40 WEEK 65,000 200
UNITS AVERAGE LEAD-TIME IN HOURS MEANTIME OVER 200 YEAR HERITAGE
- LARGEST GLOBAL DELIVERING COMPLEX BETWEEN IN DESIGN, ENGINEERING
INSTALLED BASE PROJECTS MAINTENANCE AND PRODUCTION

Hot neck
The unique hot neck arrangement,
which is part of the motor case forging, Ultra-supercritical, supercritical,
limits the transfer of heat from the
pump to the motor and negates the
subcritical capabilities
need for a separate heat barrier with OPTIONS:
independent cooling water supply.
Pumps
g Cast or forged pump case
g Single or double discharge
Motors
g Any voltage up to 11kV
g Fluid-filled wet stator or canned dry ‘seal-less’ motors

KEY FEATURES:

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
g 400 Deg C - 400 Bar g
g Meeting performance criteria on the most
demanding applications
g Reduced lead times through standardisation concept

APPLICATIONS:

Hayward Tyler offer pump solutions for:

Ultra-supercritical boiler start-up
g
Subcritical drum boiler forced 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
g

ROUTINE TESTS FOR ALL BCPs:

(included as standard)
Tilting pad design
No load test
g
All Hayward Tyler pump and cover end motor Locked rotor current test
g
radial bearings are high-capacity, asbestos-
Hydrostatic test
g
free and of the tilting pad design. They are
exceptionally tolerant to magnetite ingress
Vibration test
g
from boilers, and the pump end radial Insulation resistance and high voltage withstand test
g
bearing is positioned to minimise impeller Winding resistance test
g
overhang while limiting temperature rise. Pump performance test
g
Starting currents
g

9
Engineering capabilities.
Optimising performance and extending equipment lifetime.

Engineering
Hayward Tyler has a multi-disciplinary team of engineers Engineering competencies
including mechanical design, hydraulic and electrical engineers
along with quality and production engineers who are organised
of our world-class engineers:
in concurrent teams to deliver standard and bespoke design
Electrical analysis
g
solutions using the latest CAD modelling and simulation tools
Rotor dynamics analysis
g
to design, develop and verify the product.
Shaft deflection analysis
g
Casing stress analysis
g
Design Bearing analysis
g
For combined pump / motor products, the design process
Radial & axial thrust analysis
g
begins with hydraulic engineering to define pump capability
Hydraulic design of cooling pump
g
to meet the customer duty requirements. This is followed by
Cooling system analysis
g
selection of the appropriate motor specification to deliver the
required power to suit the customer’s on-site electrical supply Thermal analysis
g
specification. Finally, the mechanical design is developed to Internal hydraulic losses
g
produce the manufacturing and assembly design data in order Electrical losses
g
to productionise the design solution. All mechanical designs
are completed in 3D using Solidworks design package.

Verification
A number of simulation tools are utilised to verify the ANSYS Structural Analysis
performance of the designs, including Maxwell electrical g Key components including the pump case
simulation, ANSYS Computational Fluid Dynamics (CFD) for and rotating components can be analysed
hydraulic flow simulations, ANSYS Finite Elements Analysis and optimised for prolonged life at
(FEA) for structural analysis and XLrotor for torsional dynamic stricter conditions
simulation. In addition we use Motor Design Limited (MDL) g
A shorter start up time or greater
software for analysis of electrical thermal data. All designs temperature differential range can be
meet as default ASME, PED or customer specific pressure achieved through analysing effects of
standards and quality requirements such as API610, IBR thermal stresses and loading patterns
and RCCM codes. ANSYS Fluid Flow Analysis
New bearing materials are validated in Hayward Tyler’s R&D g
Accurate modelling of heat exchangers and
laboratory to assess wear resistance and durability, dimensional fluid flow within pumps ensures the correct
stability in water and other key performance parameters. Unit pressure and thermal values are obtained
electrical and hydraulic performance is validated in the test area for the application
where full scale testing can be completed, and the results fed Motor CAD Modelling
back into the design to improve correlation between simulation g Modelling to understand the thermal
and test. For new high power, high speed motor developments performance at component level; windings,
FEA tools are used for new component design and evaluation. laminations, airgap, rotor bar etc
Testing of these comprises high pressure cycling, thermal
cycling and vibration tests. Fluid dynamics are then evaluated
with a high speed rotor test rig.

10
Centre of Excellence – the most
advanced facility for specialist Centre of
motor manufacture in the world. Excellence
SPECIALIST MOTOR MANUFACTURE

Our Centre of Excellence provides cutting- State-of-the-art facilities

g
edge process capabilities, for the design and With an extension of over 2,300sq.mtrs to
the existing factory,the CoE is fitted out with
manufacture of our performance-critical motors state-of-the-art facilities such as particulate
and pumps - enabling our products to be control systems and a specialist test loop
delivered with unrivalled quality assurance Increased throughput
g
and even shorter lead times. Single process flow-lines increases
The manufacturing centre is certified as Fit for Nuclear (F4N) throughput, with thepotential to double
and ISO Class 9 nuclear compliant. We are the UK’s only capacity whilst reducing lead times
provider of industry-specific hotbed testing.
g Dedicated product build& assembly
To respond to your needs we use predictive simulation test pits
technology to emulate load effect on engineering, supply Customer units are assembled and tested
chain, production, assembly and test resources. within our access controlled ISO Class 9
clean assembly and test area
This e
 nsures we deliver orders to you right first time,
on time in full, providing you with peace of mind and Investment in training
g
confidence in our ability to deliver against our promises. Award winning investment in the learning
and developmentof our people with over
47,000 hours in 2016

“The investment in the Centre

of Excellence demonstrates our
commitment to delivering orders
at reduced lead-times and cost,
whilst ensuring right first time
customer quality.”

11
Delivering performance-critical solutions for the most demanding
requirements to meet current and future global energy needs

Boiler circulation pump standardisation for 2-pole 50Hz (2960rpm) speed

225

10.5*420A
10*450A
200 8*10*16DIFF
10x450A 7.5*381A
8x10x16A 9.5*370A
175 7*366A
7.5x381A 9.5*356A
8*356A
10.5x420A 7.5x335A
150
7x366A 11*335A
9.5x370A
11.5*348A
8x356A
125
Head m

9.5x356A
7.5x355A
11.5x348A
100
11x355A

75

50

25

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

England USA India China
Hayward Tyler Ltd Hayward Tyler Inc Hayward Tyler India Hayward Tyler
Luton, England Vermont, USA Haryana, India Shanghai, China

+44 (0)1582 731144 +1 (802) 655 4444 +91 129 251 3579/251 0124 +86 (21) 5101 2876
luton@haywardtyler.com vermont@haywardtyler.com delhi@haywardtyler.com shanghai.office@haywardtyler.com

ISO 9001 Accredited Hayward Tyler is a division of Avingtrans PLC