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PUMPS, VALVES & ACTUATORS PUMPING STATIONS OFFER TWICE THE CAPACITY


Standardised, modular pumping stations from Sulzer have cut energy demand by 40% for a Danish municipality


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ulzer has completed the first in a series of wastewater pumping stations for a Danish municipality. Replacing a pre- existing facility, the new station offers twice the capacity of the old one, while its efficient, horizontally mounted XFP pumps have cut energy demand by 40 per cent.


The project, in the Danish city of Aarhus, will be one of up to ten new pumping stations delivered under a six-year framework agreement with the municipality. Those stations will each use one of three standardised, modular designs developed by Sulzer to meet the needs of its customer. Sulzer wastewater engineers used advanced computer-aided design techniques during the development process, including the use of virtual reality technology to help the customer visualise the new concepts. Under the terms of the agreement, Sulzer will be responsible for end-to-end execution of the pumping stations, including detailed design, supply of pumps, control systems and


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pipework, installation, and the demolition of pre-existing stations. To minimise disruption during construction, the new stations make use of modular design elements and pre-cast concrete structures manufactured off site. The first station delivered under the new framework is based on the largest of the three design concepts. Its two XFP pumps, working in a duty/standby arrangement, give the station a capacity of 25l/sec. That’s double the previous station’s capacity and enough to meet expected wastewater demand in the area for the next 25 to 30 years. The station’s energy efficiency


NEW LEASE OF LIFE FOR 40 YEAR OLD PUMP


eleros Flow Technology has injected new life into a heritage pump for a Canadian heavy oil recovery customer, enabling them to increase production. The pump – a Mather & Platt BB5 – was over 40 years old and had been subject to numerous post-installation alterations. Heavy oil deposits are extremely viscous and require the injection of high pressure, high temperature steam to improve fluidity and allow the oil to be pumped to the surface. In order to boost extraction on this project, the customer needed to increase water temperatures from 90°C to 140°C. However, there were concerns that the existing pump may not be able to deliver this requirement. Nozzle loads were a particular concern. The customer turned to Celeros Flow Technology brand ClydeUnion Pumps, a preferred supplier, for assistance. Celeros Flow Technology’s aftermarket engineering team


undertook a thorough examination of the Steam Assisted Gravity Drainage (SAGD) boiler feed water pump used in the heavy oil extraction process. The investigation revealed that the pump had suffered a number of seal failures over time that had damaged the stuffing box and affected operational efficiency. There had also been no maintenance interventions for decades – but the pump had never actually failed, which was testament to its quality. Celeros Flow Technology overhauled the SAGD pump and performed a mechanical seal upgrade and Plan 23 seal flush to optimise pump performance. In addition, finite element analysis was undertaken to confirm that the nozzle loads would withstand the desired temperature increase. As a result, the pump is now capable of delivering steam at the higher temperatures required. The seal upgrades ensure it meets the latest specifications. Vivek Sahasrabuddhe, Pump Upgrades & Re-rates Lead for ClydeUnion Pumps, said: “We are really pleased with the outcome of the SAGD pump upgrade. It has not only achieved the desired production increase for the customer, but also provided a more sustainable and cost-effective solution than total pump replacement... it will continue to perform well for many more years.”


www.celerosft.com 38 APRIL 2023 | PROCESS & CONTROL


The XFP pumps work in a duty/standby arrangement and give the station a capacity of 25l/sec


improvements come from a combination of the pump design, the use of high-efficiency electric motors, and the introduction of new control systems with variable speed drives that allow the station’s output to vary smoothly in response to changes in demand. Commissioning of the station went smoothly too. Once construction was complete, the changeover from the old station took around two hours, minimising disruption to the local sewage network and eliminating the need to use tankers to remove wastewater while the system was offline.


For the municipality, using a library of standard designs will streamline the process of commissioning and constructing each pumping station under the contract, since per-project design time is minimised, and manufacturing can commence as soon as the customer is ready to initiate a project. The customer also wanted to improve working conditions for its operations and maintenance staff. All but the smallest pumping station designs use a dry-well concept, and the horizontally oriented pumps are mounted on special maintenance sleds that allow them to be decoupled and moved for maintenance without the need for heavy lifting equipment.


This means most common maintenance operations can be completed by a single operator. The use of common equipment types and design concepts across all the new pumping stations, meanwhile, will simplify spare parts management, reduce training requirements, and make it easier for staff to familiarise themselves with operations and maintenance tasks. Kenneth Larson, Technical Manager, Sulzer Pumps, said. “From concept to operation and spare parts, every aspect of our solution is designed to make the project as cost- effective and easy to run as possible.”


Sulzer www.sulzer.com


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