Pump Life Cycle Cost 8 Energy Cost Reduction
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WORKSHOP CARTAGENA - JULY 2007 Pump Life Cycle Cost Energy cost reductions using: ENERGY MANAGEMENT PROGRAMS. By: Daniel Irigo
ENERGY MANAGEMENT PROGRAMS
Pump Division
In the comparison of Life Cycle Cost for Oil & Gas industry the energy cost is a dominant part for OPEX, LCC, using 30$ per MW hour. Upstream O&G 30% of LCC Pipeline pumps (16 inch pipeline) Refineries
88% of LCC 45% of LCC
This is all under the assumption that we operate the pumps at best efficiency point, and have a pump with the highest attainable efficiency
ENERGY MANAGEMENT PROGRAMS Many pumps and pump systems use excessive energy compared to the minimum energy required to full fill the process needs.
Pump Division
This is caused by many reasons: 1. 2. 3. 4. 5. 6. 7. 8.
Pump duty was either conservative high or over specified Stream changes/part load operation Mis application Reduced demands, increased demands Demand is very variable over Life Cycle Revamps of installations Changing pump fluids (for example crude feeding the refinery has changed) etc
ENERGY MANAGEMENT PROGRAMS
Pump Division
There are large savings possible on energy costs in refineries by optimizing the pump and pump system.
ENERGY MANAGEMENT PROGRAMS IN REFINERIES
Pump Division
1) Review 20 or 30 largest power pumps of the refinery Review valve throttling, in the system Review operation near BEP. (Specially in gas scrubbing services) (Use field performance testing)
2) Define energy saving as a result of reduced valve throttling and optimized hydraulics operating near BEP 3) Review possible energy recovery for example gas scrubbing PRT instead of valve throttling.
INTRODUCTION THERE CAN BE SEVERAL REASONS FOR REVIEWING THE POSSIBLE RETROFITTING OF THE HYDRAULICS OF CENTRIFUGAL PUMPS:
Often, the off BEP operation of pumps finds its origin already at the completion of the initial equipment data sheet, as shown in the graph
HEAD
1) THE PUMP SHOULD INITIALLY HAVE BEEN SELECTED AND DESIGNED TO OPERATE AT OR CLOSE TO ITS BEST EFFICIENCY POINT (B.E.P.)
End-user margin
Contractors margin CAPACITY
Pump Division
INTRODUCTION Off-BEP Considerations Reduced Efficiency High Axial Loads High Radial Loads High Vibration Cavitation Suction Recirculation Discharge Recirculation Temperature Rise
Pump Division
INTRODUCTION BESIDES THE DIFFERENCE BETWEEN ACTUAL OPERATING POINT AND B.E.P. ON THE DATA SHEET, THERE ARE OTHER REASONS THAT COULD CAUSE THE PUMP TO OPERATE AWAY FROM B.E.P. THIS CAN BE A RESULT OF: STREAM CHANGES MISAPPLICATION REDUCED DEMANDS INCREASED DEMANDS REVAMPS
Pump Division
INTRODUCTION
Pump Division
Saddle type curve
2) THE Q-H CURVE OF THE INITIALLY INSTALLED PUMP CAN BE:
Very flat curve
Unstable curve
SADDLE TYPE
UNSTABLE THIS CAN CAUSE CONSIDERABLE PROBLEMS IN FLOW / HEAD REGULATION (CONTROL) AND ALSO IN VARIABLE SPEED AND PARALLEL PUMP OPERATION.
HEAD
TOO FLAT USABLE OPERATING WINDOW OF PUMP IF APPLIED IN PARALLEL OPERATION
CAPACITY
INTRODUCTION MANY CUSTOMERS HAVE ALREADY IDENTIFIED THE PUMP HYDRAULIC PERFORMANCE SHORT COMINGS LIKE:
NOT RUNNING AT BEP UNSTABLE OPERATION CURVE, TOO FLAT Q-H CURVE CAUSING PROBLEMS OPERATING WITH A TOO LOW EFFICIENCY PUMP
CUSTOMERS HAVE THE TENDENCY TO GO FOR COMPLETE PUMP REPLACEMENT, USING NEW ENQUIRIES
FLOWSERVE, HYDRAULIC RERATING EXPERIENCE ALLOWS FOR 90% OF THESE PUMPS TO RERATE RATHER THAN PURCHASING NEW EQUIPMENT
Pump Division
INTRODUCTION
Pump Division
HYDRAULIC RERATING IS A BETTER ECONOMIC SOLUTION THAN PURCHASING NEW PUMPS. 1)
INVESTMENT NEW PUMPS
=
COST TO PURCHASE NEW PUMP X FACTOR
THE FACTOR COMPRISES OF COST FOR AMONGST OTHERS: CUSTOMER S ENGINEERING AND PURCHASING GROUP ENGINEERING COMPANY FOUNDATION (NEW OR MODIFIED) PIPING CHANGES TO TIE IN THE NEW PUMP IN THE EXISTING SYSTEM INSTRUMENTATION TIE-IN, ERECTION TIME, POSSIBLY IMPOSING PRODUCTION LOSSES LINE FLUSHING AND COMMISSIONING ETC. CAUSE THE COST OF INVESTMENT TO RISE FAR ABOVE THE PRICE OF THE NEW PUMP.
FACTOR = 1,5 to 3
INTRODUCTION
2)
Pump Division
INVESTMENT HYDRAULIC RERATING OF EXISTING PUMPS IN AVERAGE BETWEEN 40 TO 75 % OF THE PRICE OF A NEW PUMP IMPLEMENTATION CAN BE VERY FAST COMPARED TO REPLACING THE PUMP. Note: If hydraulic re-rate is done when a pump is up for a major overhaul, the actual investment is considerably lower than the mentioned percentage. This is caused by the fact that the cost for a major overhaul of the pump might already be 50 to 75% of the total cost for the re-rate.
Pump Division
REDUCED FLOW / HEAD DEMANDS What is so special about changing the hydraulic performance?
Just reduce impeller diameter
just install large impeller diameter This indeed can be the correct method. The family curves of the pumps will tell what the possibilities would be (the window in which changes can be made within the given pump).
Pump Division
Q-H AND
CHARACTERISTICS
HYDRAULIC RERATING
THEORETICAL IMPELLER/VOLUTE CURVE
H
ø
HYDRAULIC RERATING
Pump Division
CHANGING IMPELLER/VOLUTE CHARACTERISTICS 1) IMPELLER, STEEPER Q-H LINE
OLD DUTY POINT
NUMBER OF VANES
OUTLET BLADE ANGLE
BA OF IMPELLER
2) VOLUTE, FLATTER CHARACTERISTIC. CHANGE VOLUTE
THROAT AREA
(LARGER)
VOLUTE LIP ANGLE CHANGED
NEW DUTY POINT
HYDRAULIC RERATING CHANGING IMPELLER/VOLUTE CHARACTERISTICS
Other considerations:
Maximum attainable efficiency (Andersen curve)
HEAD / CAP ACI
TY
VOLUTE
EF FI CI EN CY
Volute or diffuser
BEP DIFUSSER
Pump Division
Pump Division
Impeller or Volute Modifications
HYDRAULIC RERATING Changing Impeller Hydraulics...
Pump Division
Modification Of Volute... Volute Chip
Pump Division
Pump Division
Volute Lip Insert
Modification Of Volute... Throat Insert
Pump Division
HYDRAULIC RERATING Volute inserts
Pump Division
REDUCED FLOW/HEAD DEMANDS
Pump Division
LOW FLOW IMPELLER, FLAT SYSTEM RESISTANCE LINE
H THE EXAMPLE IN FIGURE 1 IN BOLD LINES IS A SINGLE STAGE DOUBLE SUCTION, BETWEEN BEARING PROCESS TYPE PUMP, MODIFIED FOR A 55% REDUCTION IN FLOW AGAINST A HIGH HEAD. Figure 1
Q
Pump Division
REDUCED FLOW/HEAD DEMANDS LOW FLOW IMPELLER, FLAT SYSTEM RESISTANCE LINE WE INSTALLED A SPECIFICALLY DESIGNED LOW FLOW IMPELLER AND OVERSIZED WEARRINGS, SHOWN IN FIGURE 2. NOTE THE DIFFERENCES IN PUMP PERFORMANCE WITH THIS MODIFICATION.
Low capacity impeller producing approx. the same head at approx. half the capacity
REDUCED FLOW/HEAD DEMANDS
Pump Division
LOW FLOW IMPELLER WITH INSERT FOR STEEP RESISTANCE LINES
SHOWN IN FIGURE 3 IN BOLD LINES IS A SINGLE STAGE SINGLE SUCTION, CANTILIVERED PROCESS PUMP, MODIFIED FOR A 50% REDUCTION IN FLOW AGAINST A 45% REDUCTION IN HEAD.
FIGURE 3
H
Q
REDUCED FLOW/HEAD DEMANDS
LOW FLOW IMPELLER WITH INSERT FOR STEEP RESISTANCE LINES
Figure 4
Pump Division
Pump Division
REDUCED FLOW/HEAD DEMANDS
volute insert
THE FABRICATED INSERT IS A FOUR PORT VOLUTE SHOWN IN FIGURE 5 WHICH BOLTS AGAINST THE PUMPCOVER.
FIGURE 5
Pump Division
REDUCED FLOW/HEAD DEMANDS DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
SHOW IN FIGURE 6 IN BOLD LINES IS A MULTIPLEX PUMP, MODIFIED FOR A 17% REDUCTION IN HEAD AT THE DESIGN FLOW.
H WE REMOVED ONE IMPELLER FROM THE SHAFT AND INSTALLED A DESTAGE BUSHING IN THE VOLUTE BORE, SHOWN IN FIGURE 7. Figure 6
REDUCED FLOW/HEAD DEMANDS Pump Division
DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
IN THIS EXAMPLE, THE RESULTING UNBALANCED THRUST WAS WITHIN THE THRUST BEARING CAPABILITY AND THE BALANCE SLEEVE AND BUSHING WERE NOT REPLACED FOR A DIFFERENT BALANCE.
FLOWSERVE HAS THE CAPABILITY TO MODIFY ANY MULTISTAGE PUMP FOR MOST REDUCED HEAD/FLOW APPLICATIONS SIMILAR TO THE EXAMPLES GIVEN.
REDUCED FLOW/HEAD DEMANDS Pump Division
DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
DESTAGE BUSHING BLINDING THE VOLUTE OF THE 4TH STAGE AND CREATING A SHORT CUT TO THE SUCTION BOX OF THE NEXT IMPELLER
Pump Division
ENERGY MANAGEMENT PROGRAM
ENERGY MANAGEMENT PROGRAMS
Pump Division
In the comparison of Life Cycle Cost for Oil & Gas industry the energy cost is a dominant part for OPEX, LCC, using 30$ per MW hour. Upstream O&G 30% of LCC Pipeline pumps (16 inch pipeline) Refineries
88% of LCC 45% of LCC
This is all under the assumption that we operate the pumps at best efficiency point, and have a pump with the highest attainable efficiency
ENERGY MANAGEMENT PROGRAMS Many pumps and pump systems use excessive energy compared to the minimum energy required to full fill the process needs.
Pump Division
This is caused by many reasons: 1. 2. 3. 4. 5. 6. 7. 8.
Pump duty was either conservative high or over specified Stream changes/part load operation Mis application Reduced demands, increased demands Demand is very variable over Life Cycle Revamps of installations Changing pump fluids (for example crude feeding the refinery has changed) etc
ENERGY MANAGEMENT PROGRAMS
Pump Division
There are large savings possible on energy costs in refineries by optimizing the pump and pump system.
ENERGY MANAGEMENT PROGRAMS IN REFINERIES
Pump Division
1) Review 20 or 30 largest power pumps of the refinery Review valve throttling, in the system Review operation near BEP. (Specially in gas scrubbing services) (Use field performance testing)
2) Define energy saving as a result of reduced valve throttling and optimized hydraulics operating near BEP 3) Review possible energy recovery for example gas scrubbing PRT instead of valve throttling.
INTRODUCTION THERE CAN BE SEVERAL REASONS FOR REVIEWING THE POSSIBLE RETROFITTING OF THE HYDRAULICS OF CENTRIFUGAL PUMPS:
Often, the off BEP operation of pumps finds its origin already at the completion of the initial equipment data sheet, as shown in the graph
HEAD
1) THE PUMP SHOULD INITIALLY HAVE BEEN SELECTED AND DESIGNED TO OPERATE AT OR CLOSE TO ITS BEST EFFICIENCY POINT (B.E.P.)
End-user margin
Contractors margin CAPACITY
Pump Division
INTRODUCTION Off-BEP Considerations Reduced Efficiency High Axial Loads High Radial Loads High Vibration Cavitation Suction Recirculation Discharge Recirculation Temperature Rise
Pump Division
INTRODUCTION BESIDES THE DIFFERENCE BETWEEN ACTUAL OPERATING POINT AND B.E.P. ON THE DATA SHEET, THERE ARE OTHER REASONS THAT COULD CAUSE THE PUMP TO OPERATE AWAY FROM B.E.P. THIS CAN BE A RESULT OF: STREAM CHANGES MISAPPLICATION REDUCED DEMANDS INCREASED DEMANDS REVAMPS
Pump Division
INTRODUCTION
Pump Division
Saddle type curve
2) THE Q-H CURVE OF THE INITIALLY INSTALLED PUMP CAN BE:
Very flat curve
Unstable curve
SADDLE TYPE
UNSTABLE THIS CAN CAUSE CONSIDERABLE PROBLEMS IN FLOW / HEAD REGULATION (CONTROL) AND ALSO IN VARIABLE SPEED AND PARALLEL PUMP OPERATION.
HEAD
TOO FLAT USABLE OPERATING WINDOW OF PUMP IF APPLIED IN PARALLEL OPERATION
CAPACITY
INTRODUCTION MANY CUSTOMERS HAVE ALREADY IDENTIFIED THE PUMP HYDRAULIC PERFORMANCE SHORT COMINGS LIKE:
NOT RUNNING AT BEP UNSTABLE OPERATION CURVE, TOO FLAT Q-H CURVE CAUSING PROBLEMS OPERATING WITH A TOO LOW EFFICIENCY PUMP
CUSTOMERS HAVE THE TENDENCY TO GO FOR COMPLETE PUMP REPLACEMENT, USING NEW ENQUIRIES
FLOWSERVE, HYDRAULIC RERATING EXPERIENCE ALLOWS FOR 90% OF THESE PUMPS TO RERATE RATHER THAN PURCHASING NEW EQUIPMENT
Pump Division
INTRODUCTION
Pump Division
HYDRAULIC RERATING IS A BETTER ECONOMIC SOLUTION THAN PURCHASING NEW PUMPS. 1)
INVESTMENT NEW PUMPS
=
COST TO PURCHASE NEW PUMP X FACTOR
THE FACTOR COMPRISES OF COST FOR AMONGST OTHERS: CUSTOMER S ENGINEERING AND PURCHASING GROUP ENGINEERING COMPANY FOUNDATION (NEW OR MODIFIED) PIPING CHANGES TO TIE IN THE NEW PUMP IN THE EXISTING SYSTEM INSTRUMENTATION TIE-IN, ERECTION TIME, POSSIBLY IMPOSING PRODUCTION LOSSES LINE FLUSHING AND COMMISSIONING ETC. CAUSE THE COST OF INVESTMENT TO RISE FAR ABOVE THE PRICE OF THE NEW PUMP.
FACTOR = 1,5 to 3
INTRODUCTION
2)
Pump Division
INVESTMENT HYDRAULIC RERATING OF EXISTING PUMPS IN AVERAGE BETWEEN 40 TO 75 % OF THE PRICE OF A NEW PUMP IMPLEMENTATION CAN BE VERY FAST COMPARED TO REPLACING THE PUMP. Note: If hydraulic re-rate is done when a pump is up for a major overhaul, the actual investment is considerably lower than the mentioned percentage. This is caused by the fact that the cost for a major overhaul of the pump might already be 50 to 75% of the total cost for the re-rate.
Pump Division
REDUCED FLOW / HEAD DEMANDS What is so special about changing the hydraulic performance?
Just reduce impeller diameter
just install large impeller diameter This indeed can be the correct method. The family curves of the pumps will tell what the possibilities would be (the window in which changes can be made within the given pump).
Pump Division
Q-H AND
CHARACTERISTICS
HYDRAULIC RERATING
THEORETICAL IMPELLER/VOLUTE CURVE
H
ø
HYDRAULIC RERATING
Pump Division
CHANGING IMPELLER/VOLUTE CHARACTERISTICS 1) IMPELLER, STEEPER Q-H LINE
OLD DUTY POINT
NUMBER OF VANES
OUTLET BLADE ANGLE
BA OF IMPELLER
2) VOLUTE, FLATTER CHARACTERISTIC. CHANGE VOLUTE
THROAT AREA
(LARGER)
VOLUTE LIP ANGLE CHANGED
NEW DUTY POINT
HYDRAULIC RERATING CHANGING IMPELLER/VOLUTE CHARACTERISTICS
Other considerations:
Maximum attainable efficiency (Andersen curve)
HEAD / CAP ACI
TY
VOLUTE
EF FI CI EN CY
Volute or diffuser
BEP DIFUSSER
Pump Division
Pump Division
Impeller or Volute Modifications
HYDRAULIC RERATING Changing Impeller Hydraulics...
Pump Division
Modification Of Volute... Volute Chip
Pump Division
Pump Division
Volute Lip Insert
Modification Of Volute... Throat Insert
Pump Division
HYDRAULIC RERATING Volute inserts
Pump Division
REDUCED FLOW/HEAD DEMANDS
Pump Division
LOW FLOW IMPELLER, FLAT SYSTEM RESISTANCE LINE
H THE EXAMPLE IN FIGURE 1 IN BOLD LINES IS A SINGLE STAGE DOUBLE SUCTION, BETWEEN BEARING PROCESS TYPE PUMP, MODIFIED FOR A 55% REDUCTION IN FLOW AGAINST A HIGH HEAD. Figure 1
Q
Pump Division
REDUCED FLOW/HEAD DEMANDS LOW FLOW IMPELLER, FLAT SYSTEM RESISTANCE LINE WE INSTALLED A SPECIFICALLY DESIGNED LOW FLOW IMPELLER AND OVERSIZED WEARRINGS, SHOWN IN FIGURE 2. NOTE THE DIFFERENCES IN PUMP PERFORMANCE WITH THIS MODIFICATION.
Low capacity impeller producing approx. the same head at approx. half the capacity
REDUCED FLOW/HEAD DEMANDS
Pump Division
LOW FLOW IMPELLER WITH INSERT FOR STEEP RESISTANCE LINES
SHOWN IN FIGURE 3 IN BOLD LINES IS A SINGLE STAGE SINGLE SUCTION, CANTILIVERED PROCESS PUMP, MODIFIED FOR A 50% REDUCTION IN FLOW AGAINST A 45% REDUCTION IN HEAD.
FIGURE 3
H
Q
REDUCED FLOW/HEAD DEMANDS
LOW FLOW IMPELLER WITH INSERT FOR STEEP RESISTANCE LINES
Figure 4
Pump Division
Pump Division
REDUCED FLOW/HEAD DEMANDS
volute insert
THE FABRICATED INSERT IS A FOUR PORT VOLUTE SHOWN IN FIGURE 5 WHICH BOLTS AGAINST THE PUMPCOVER.
FIGURE 5
Pump Division
REDUCED FLOW/HEAD DEMANDS DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
SHOW IN FIGURE 6 IN BOLD LINES IS A MULTIPLEX PUMP, MODIFIED FOR A 17% REDUCTION IN HEAD AT THE DESIGN FLOW.
H WE REMOVED ONE IMPELLER FROM THE SHAFT AND INSTALLED A DESTAGE BUSHING IN THE VOLUTE BORE, SHOWN IN FIGURE 7. Figure 6
REDUCED FLOW/HEAD DEMANDS Pump Division
DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
IN THIS EXAMPLE, THE RESULTING UNBALANCED THRUST WAS WITHIN THE THRUST BEARING CAPABILITY AND THE BALANCE SLEEVE AND BUSHING WERE NOT REPLACED FOR A DIFFERENT BALANCE.
FLOWSERVE HAS THE CAPABILITY TO MODIFY ANY MULTISTAGE PUMP FOR MOST REDUCED HEAD/FLOW APPLICATIONS SIMILAR TO THE EXAMPLES GIVEN.
REDUCED FLOW/HEAD DEMANDS Pump Division
DESTAGING, OF MULTISTAGE PUMPS FOR REDUCED HEADS
DESTAGE BUSHING BLINDING THE VOLUTE OF THE 4TH STAGE AND CREATING A SHORT CUT TO THE SUCTION BOX OF THE NEXT IMPELLER
Pump Division
ENERGY MANAGEMENT PROGRAM
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