Nine years of energy inefficiency, fixed in five months with an energy-efficient pump retrofit

Customer
 A large chemicals producer
Location Western China
Industry
 		Petrochemicals
Key Services

The Challenge

An energy-guzzling pump takes its toll

  • The customer noticed that an essential lean methanol pump was running inefficiently.
  • The pump was used to move syngas into a scrubber, where it could be purified of carbon dioxide, hydrogen sulfide, and carbonyl sulfide – an essential process in petrochemical applications.
  • The Chinese OEM pump had been installed in 2014 and had been running for nine years.
  • It began to show signs of wear, consuming much more energy than it had previously required. The customer was also looking for ways to adapt the pump to new process requirements, which included:
    -  Reducing the pressure of the pump from 1,027m to 870m
    -  Bringing the pump up to the API 610 standard for centrifugal pumps. This would mean mounting the pump on the centerline and changing the suction piping to an alternative designed to withstand higher pressure.
  • To make the challenge even greater, the customer needed to make these changes without modifying auxiliary equipment like the base plate and discharge piping.
  • Faced with such a complex task, the customer called in Sulzer for support.
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The Solution

Efficiency in every feature

  • We began a complete Stage I and Stage II analysis, using PumpWise, our proprietary digital tool which calculates and uncovers energy and carbon reduction potential for centrifugal pumps.
  • Pump had operated at 69% efficiency. But after nine years of operation, the operational efficiency had dropped to just 61%.
  • The Stage I analysis revealed that the new duty point of the pump (870m) was below the minimum diameter range for the pump’s impeller.
  • During the Stage II analysis, we began drawing up a strategy inclusive of a new hydraulics, to get the pump working as efficiently as possible and bring it up to API 610 standard.
  • We recommended a direct replacement via customised new Sulzer pump, which would offer enhanced hydraulic coverage than the original.  This pump would operate at 97% efficiency, which would be a major improvement over the current solution.

The retrofitted pump was the ideal way to help the customer address their challenges, featuring:

  • Side suction with a top discharge pipe to match the existing pipe.
  • An API 610-compliant centerline-mounted barrel design.
  • A pump suction region rated for 900# to meet the requirements of API 610 (12th edition).
  • A dynamically balanced rotor to ensure smooth and reliable operation.
  • An innovative cartridge design which means the bundle can be removed without major disassembly, saving time on repairs and maintenance.

Crucially, this compact “drop-in” GSG pump could be implemented on the existing base plate and make use of the existing motor and lube oil station, with no modification needed.

Explore our solutions

  • Sulzer Energy Optimization Pump Services
    Energy optimization service
    Sulzer sets a new standard for the future of pump operations, improving the operational, environmental and financial performance of pump operators around the world.
  • oem_x_line_key_visual_1_final_1920w_x1280h
    OEM-X Line
    Outages and downtime are costly. Even worse, rotating machinery and pumps face numerous specific challenges, many of which are hard to isolate. Choosing the right supplier is vital when you factor in high maintenance levels and running costs of critical equipment.
  • Engineer performing retrofit service
    Retrofit
    Retrofitting your critical assets with the latest technology will maximize performance, minimize costs, and improve reliability.

The Customer Benefit

Efficiency gains exceed everyone’s expectation

  • Thanks to our rapid manufacturing capabilities and expert support, the pump was fitted and running just five months after the customer reached out to us.
  • Before installation, we estimated that the pump would deliver a 13% improvement in efficiency compared to the existing pump. But practical testing showed that we had underestimated the potential efficiency gains.
  • In fact, after running the pump for 120 hours, we found that it improved efficiency by an incredible 28% – a huge saving.
  • Multiplied across a whole year, those efficiency savings add up to US$163,111 – meaning that the retrofitting project will have paid for itself within just 15 months.
  • Cutting back on energy use to this extent also means that the customer will save around 26.7 tons of carbon every year.
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