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.
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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

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.

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.
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