WORKSHOP

CARTAGENA - JULY 2007

Pump Life Cycle Cost
Energy cost reductions using:
ENERGY MANAGEMENT PROGRAMS.

By: Daniel Irigo

 ENERGY MANAGEMENT Pump Division

PROGRAMS
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 88% of LCC

(16 inch pipeline)
Refineries 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 Pump Division

PROGRAMS
Many pumps and pump systems use
excessive energy compared to the minimum
energy required to full fill the process needs.
This is caused by many reasons:
1. Pump duty was either conservative high or over specified
2. Stream changes/part load operation
3. Mis application
4. Reduced demands, increased demands
5. Demand is very variable over Life Cycle
6. Revamps of installations
7. Changing pump fluids (for example crude feeding the refinery has
changed)
8. etc
 ENERGY MANAGEMENT Pump Division

PROGRAMS

There are large savings possible on energy

costs in refineries by optimizing the pump and
pump system.
 ENERGY MANAGEMENT Pump Division

PROGRAMS IN REFINERIES

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 Pump Division

THERE CAN BE SEVERAL REASONS FOR REVIEWING THE POSSIBLE

RETROFITTING OF THE HYDRAULICS OF CENTRIFUGAL PUMPS:

1) THE PUMP SHOULD INITIALLY HAVE BEEN SELECTED AND DESIGNED TO

OPERATE AT OR CLOSE TO ITS BEST EFFICIENCY POINT (B.E.P.)

Often, the off BEP operation of

pumps finds its origin already

HEAD
at the completion of the initial
equipment data sheet, as
shown in the graph
End-user margin
Contractors margin

CAPACITY
 INTRODUCTION Pump Division

Off-BEP Considerations

Reduced Efficiency
High Axial Loads
High Radial Loads
High Vibration
Cavitation
Suction
Recirculation
Discharge
Recirculation
Temperature Rise
 INTRODUCTION Pump Division

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
 INTRODUCTION Pump Division

Saddle type curve

2) THE Q-H CURVE OF THE INITIALLY Very flat curve

INSTALLED PUMP CAN BE:
Unstable curve
SADDLE TYPE

TOO FLAT

HEAD
UNSTABLE USABLE OPERATING
WINDOW OF PUMP IF
APPLIED IN PARALLEL
THIS CAN CAUSE CONSIDERABLE OPERATION
PROBLEMS IN FLOW / HEAD
REGULATION (CONTROL) AND ALSO IN
VARIABLE SPEED AND PARALLEL CAPACITY
PUMP OPERATION.
 INTRODUCTION Pump Division

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
 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 Pump Division

2) 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

H
THEORETICAL
IMPELLER/VOLUTE
CURVE

ø
 Pump Division

HYDRAULIC RERATING

CHANGING IMPELLER/VOLUTE CHARACTERISTICS

OLD DUTY POINT

1) IMPELLER, STEEPER Q-H LINE
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
 Pump Division

HYDRAULIC RERATING

CHANGING IMPELLER/VOLUTE CHARACTERISTICS

HEAD
/ CAP
Other considerations: ACI TY

Maximum attainable
efficiency (Andersen
curve) VOLUTE
Volute or diffuser

CY
EN
CI
EF
FI BEP

DIFUSSER
 Pump Division

Impeller or Volute Modifications

 HYDRAULIC RERATING Pump Division

Changing Impeller Hydraulics...

 Pump Division

Modification Of Volute...
Volute Chip
 Pump Division

Volute Lip Insert

 Pump Division

Modification Of Volute...
Throat Insert
 HYDRAULIC RERATING Pump Division

Volute inserts
 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,
Q
BETWEEN BEARING
PROCESS TYPE PUMP,
MODIFIED FOR A 55%
REDUCTION IN FLOW
AGAINST A HIGH HEAD.

Figure 1
 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 DEMANDSPump Division

LOW FLOW IMPELLER

WITH INSERT FOR STEEP
RESISTANCE LINES

SHOWN IN FIGURE 3 IN
BOLD LINES IS A SINGLE
STAGE SINGLE SUCTION, H
CANTILIVERED PROCESS
PUMP, MODIFIED FOR A
50% REDUCTION IN FLOW
AGAINST A 45%
REDUCTION IN HEAD. Q

FIGURE 3
 Pump Division

REDUCED FLOW/HEAD DEMANDS

LOW FLOW
IMPELLER WITH
INSERT
FOR STEEP
RESISTANCE LINES

Figure 4
 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