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RetrofitRetrofitting your critical assets with the latest technology will maximize performance, minimize costs, and improve reliability.
NOC achieves massive Pumps’ energy savings for Offshore operations
| Customer | European NOC |
|
Location |
North Sea |
| Industry |
Upstream O&G |
|
Key Services |
|
OPEX SAVINGS
5.3 million
euros/year
ENERGY REDUCTION GUARANTEE
2
%
ENERGY SAVINGS OUTCOME
>5
%
ENERGY CONSUMPTION SAVINGS
2'800
MWh/year
CARBON REDUCTION
7'751
tonnes/year
OPEX CUT
1 million
euros
The Challenge
An ambitious plan to obtain efficiency improvement while reducing carbon footprint liability
- The existing pumps had performed reliably for more than 10 years but were due for routine overhaul.
- The assessment was that the pumps were mechanically sound – with high reliability since installation.
- Hydraulically, ‘as new’ performance had been maintained, signifying minimal wear rates.
- But in view of the relatively high power consumption (circa 1.6MW consumed by 4 pumps) the client was interested in obtaining efficiency improvements as a way of reducing the platform’s Carbon Emissions liability.
The Solution
Uncovering and maximizing energy efficiency potential via retrofit
- While pumps had performed well, Sulzer’s assessment was that efficiency fell some 2 to 3 points lower than expected from a modern hydraulic.
- A hydraulic upgrade was proposed, comprising a new internal hydraulic bundle, designed to fit within the existing barrel.
- Existing end covers, barrel closure, bearings, seal and drive coupling would be retained.
- A guaranteed 2% reduction in power consumed formed a part of the contract.
- Power savings were to be obtained by a combination of:
- Modern Sulzer hydraulics.
- Tighter running clearances with a combination of PEEK and SUME coated wear parts. - “Before and After” tests would be performed on site to verify performance improvements
The Customer Benefit
Overachievement yields outstanding monetary & emissions benefits
- Minimal down time – design and manufacture of the new hydraulic bundle was carried out in advance, enabling the upgrade to be performed as part of a planned overhaul.
- Site footprint and interfaces remained unchanged.
- Site testing verified >5% saving in power consumed by the first new pump when run in parallel with unmodified pumps.
- Client has achieved significant power and Emissions savings as a result.
- Costs were minimised by carrying out the upgrade in conjunction with a planned overhaul.