Efficient custom pump solution Bespoke pumps deliver 50% cost savings to Korean power plant

After a comprehensive technical study of the existing installation, Sulzer's team of specialists proposed a drop-in, custom pump design. The custom pump solution provided the power plant with time and value advantages compared to other options and a swift, optimal replacement.

power station at night

Customer

Major combined cycle power plant

Location

Ansan City, South Korea

Industry

Power generation

Key services

PUMPS RETROFITTED

28 year old

COST SAVINGS

50 %

RETROFITTED FLOW RATE

260 m3 /h
132 bar G 

ENERGY EFFICIENCY

3’490 rpm / 1'235 kW

REDUCED VIBRATION

2 mm/s

THE IMPACT

The pumps delivered a sizeable reduction in capital expenditure and a swift, optimal replacement for the power plant.

The challenge

Korean OEM pumps proved costly as maintenance interventions increased

After 28 years in service, a drop in performance and intense vibration at 8 mm/s was detected by power plant operators on four ring-section boiler feed pumps. The increased frequency of interventions and lack of support from the local Korean pump OEM meant that the power plant needed an alternate pump repair specialist to provide a solution. Due to positive experiences operating its pumps across multiple facilities, site managers contacted Sulzer.

  • The pumps required more frequent maintenance than the typical three-year service interval
  • Any pump failure risked power generation uptime, energy supply and penalties from the regulatory body
  • Site managers needed expert insight in how to approach the pump issues
  • Any pump maintenance needed to take place within a planned shutdown
  • Little support was available from the pump OEM
 Gallery
Damaged korean OEM pump
korean engineers installing retrofitted pumps
pump in packaging
Korea engineers working on pumps
sulzer retrofit boiler feed pump

The solution

Bespoke turn-key drop-in solution with training

Sulzer’s team of specialist pump and mechanical engineers, offering decades of power generation experience, conducted a comprehensive technical study of the existing installation. Evaluating the pump’s condition, they determined that the pumps had reached the end of their service life. Leveraging its engineering expertise as a leading global pump OEM, Sulzer proposed a drop-in, custom pump design.

  • A fully customized, plug-and-play pump was provided with a hydraulic design based on the MD series
  • Optimized pump delivered the same performance with improved efficiency
  • Pumps were designed, manufactured and tested ahead of planned shutdown
  • The supply of automatic recirculation (ARC) valves, drive couplings, seals and lube oil pipework ensured a turnkey solution
  • A training package was included for plant operators to support future pump maintenance

Explore our solutions

  • Inspection and Analysis
    Inspection and analysis
    Inspection and analysis provides you with the confidence of knowing the condition of your equipment. Maintenance and overhauls reduce the risk of failure and additional costs and knowing the condition of your equipment provides an opportunity for modifications to reach optimized performance levels.
  • Sulzer Academy for Pumps and Systems
    Sulzer Academy
    The Sulzer Academy offers comprehensive courses to help better understand centrifugal pumps and associated auxiliary equipment used in participant’s facilities.

The customer benefit

Superior cost savings and life-time support for revitalized pumps

The custom pump solution provided the power plant with time and value advantages compared to other options. Furthermore, the plant received a turnkey, drop-in pump replacement that required minimal modifications to existing facility infrastructure. Pump changeover was completed within the planned shutdown, securing power generation uptime.

  • Plug-and-play design ensured that Sulzer field service teams could complete pump changeover in two weeks
  • The custom pump solution delivered a 50% cost saving compared to an OEM replacement
  • Sulzer avoided the expensive base plate, suction and discharge pipework changes proposed by local Korean OEM
  • After more than two years of reliable operation, the Sulzer pumps have delivered improved efficiency and vibrations of only 2 mm/s
  • Full product lifecycle support is available, including just in time (JIT) spares supply
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