CompressorTechTwo - 2010 (Sample)

HIEC’s vertically integrated plant is ISO 9001 certified. A full electrical and mechanical engineering staff designs controls, mechanical components and enclosures. The plant manufactures everything except forgings and machining of the largest rotor shafts. Enclosures are also designed in-house, and all are manufactured in-house except for water-to-air and air-to-air heat exchangers. The 280,000 sq.ft. ( 26,013 m2) facility is located on a 29 acre ( 11. 7 ha) site. A new 50,000 sq.ft. (4643 m2) addition was completed in 2009, which will provide more manufacturing space for moving assembly farther way from the fabrication and welding processes.

“Customers have demanded, and will continue to demand, improvements in performance and quality of products. This is seen in the extensive amount of testing our customers require of their motor and generator suppliers before equipment is delivered. Our test floor allows for complete testing of synchronous motors and generators in vertical and horizontal configurations and full load testing of induction motors up to 8000 hp (5966 kW), at voltages from 240 volts to 13. 8 kV, and at 60 and 50 Hz,” said Smollen. The test floor consists of two vertical test pits and two test bedplates for horizontal machines. Each test bedplate has a weight in excess of 1 million lb. (454,000 kg), ensuring a capability to meet or exceed the stringent 0.02 in./sec (0.5 mm/sec) industry vibration criteria for massive, rigid mounting.

In-house testing can meet all third-party requirements, such as API, DNV, ABS, Lloyds, CSA, CENELEC and oth-

This 10,000 hp (7457 k W), 1800 rpm, four-pole, high-voltage HIEC
synchronous motor drives a compressor used in a Texas, U.S.A.,
pipeline transmission installation.

with output voltages of 380 to 15,000 volts. Generators and motors can be furnished with a variety of enclosures, ranging from open type to totally enclosed type with air-to-water or air-to-air heat exchangers. A complete range of accessories and protective devices is available. “HIEC is the market leader in medium power generators for gas, steam and hydro turbines, and diesel engines, up to 20 mVA,” said Smollen.

HIEC provides custom designs and supplies complete packages, including motor starters, controls, switchgear, safety systems, breakers and switching equipment. “We have the rotating equipment experience and knowledge needed to provide reliable, economical switchgear and control system designs,” said Mark Phillips, project manager. “This allows for sole sourcing of a coordinated electrical package. Our controls are designed to interface with any type of prime mover, including gas and steam turbines, reciprocating engines and hydro turbines,” he explained.

The company also builds synchronous condensers, which are fundamentally a synchronous motor that is not connected to any driven load. Once started and connected to the electrical system, it operates at full leading power factor to put reactive power or volt-ampere reactive (VAR) into the network to support the system voltage or maintain the system power factor at the desired level. Power factors below 1.0 require a utility to generate more than the minimum number of volt-amperes necessary to supply the real power in watts. This increases generation and transmission costs, which power companies pass through to customers. Synchronous condensers can therefore result in large reductions in electricity cost for large users.

ers. The test facility includes capabilities such as performance, temperature and efficiency testing per IEEE 112 and 115, IEC 34 and other standards. The facility includes a state-of-the-art data acquisition system, Bentley-Nevada vibration monitoring system and complete control from the master control room overlooking the test floor area.

HIEC provides factory rebuilds, re-furbishments and repairs of customer-owned motors and generators, mostly those originally manufactured by Ideal, but also other manufacturers, which it described as a growing market segment. The company also provides technical support and a fit-to-foundation service, where a team goes to an existing site and takes measurements to custom engineer an Ideal motor to replace an old (other OEM) motor, fitting it into the existing mounting and footprint.

HIEC prides itself in providing good upfront support in managing projects and good after-sales support for customers. Sales are handled from the Mansfield office or from a sales office in Houston, Texas, U.S.A.

“HIEC designs are very conservative and rugged,” said Smollen. “Life of our equipment is typically 30 years or more, and we have equipment running since the 1940s and 1950s. The Ideal tradition is carried forward by our 250-plus employees. Some of our current workers have relatives who were with Ideal when the company was formed. The average employee has over 20 years’ experience with the company. This experience and pride result in excellent workmanship. These skills are complemented by an experienced custom design engineering staff. The unique combination of engineering and manufacturing experience, developed over 100 years, ensures high quality in every product,” he concluded. ;