FEATURE u Pumps & Pumping Systems
A straightforward solution to a complex problem
Sulzer delivers targeted pump refurbishment that achieves 50 per cent cost saving
O
ne of the largest oil refineries on the island of Java, Indonesia, recently relied on the specialist knowledge of Sulzer to refurbish and modernise eight of its diesel pumps. The targeted overhaul program
helped the equipment attain a new operating point, providing a 50 per cent cost saving compared to purchasing new units and five-month overall lead time reduction. As part of this initiative, the pumps (used to transfer fuel from the refinery)
were using six diesel drives and two steam turbines for power. One of the assets dated from 1975, and there was no existing documentation available on site for any of the units. As a result, operators were unsure how to improve the performance of the pumps to meet the increased fuel demand while safeguarding reliability. Consequently, the engineering contractor approached a number of pump specialists to see how a new duty point could be effectively achieved. Utilising its knowledge as a global pump OEM, Sulzer is an expert in carrying
out retrofits and refurbishments for equipment used in a wide range of applications. This ensures that higher reliability and efficiency standards can be achieved with optimised overhaul projects. Consequently, Sulzer engineers have unrivalled experience in working with legacy pumps.
LOCAL EXPERTISE WITH GLOBAL SUPPORT Sulzer’s local service centre in Indonesia provided seamless access to engineering services and the company’s wider global network. To overcome the lack of documentation, the Indonesian team contacted Sulzer Pumps UK. The UK team was able to source all the documentation and data for the diesel pumps installed at the refinery. With this information, the team in Indonesia closely collaborated with the Sulzer Pumps engineering team in the USA, and as well as this, the Singapore Service Centre acted as a central hub for all the teams to organize their findings and recommendations. After close international collaboration, it was clear that the new duty point could be met without any modifications to the pumps themselves.
Sulzer Indonesia carried out detailed inspections of the units and conducted a full refurbishment of the pumps, bringing them back to as-new standard.
GEARING UP
Rather than modifying the pumps, new gearboxes would be used to increase the speed of the pumps to reach the new process requirements, which could be achieved well within the performance envelope of the units. Armed with this information and a plan of action, Sulzer Indonesia
carried out detailed inspections of the units. The team then conducted a full refurbishment of the eight pumps, bringing them back to as-new standard. New skid frames were fitted with efficient electric motors connected to gearboxes to deliver the desired speed increase, replacing the old diesel drives and steam turbines. To ensure a complete drivetrain package, Sulzer also installed new couplings and lube oil systems. The rebuilt skids were a plug and play solution, allowing simple reconnection with existing refinery pipework, unlocking a quick installation and minimizing time on site. This approach not only ensured a reduced lead time on the project, but also meant the retrofit could be carried out at 50 per cent of the cost of sourcing new pumps. Furthermore, the retrofit offered a time saving of five months compared to delivering replacement units. No modifications to the pumps themselves also allowed easy plug and play reintegration into the surrounding process equipment back at the refinery once work was complete. What had initially been a complex problem was solved with a straightforward solution that saved time and costs. Updating the drive technology for the pumps ensured that the new duty point was also met with increased efficiency. By using the operational data for the pumps, the complex new performance requirements could be met with speed increasing gearboxes, with future system reliability assured. Sulzer’s capabilities ensured that a complex application challenge was met with a faster solution that offered increased value compared to ordering all new pumps. The think global – act local philosophy at Sulzer enabled seamless
information sharing and collaboration during the project. The depth of Sulzer engineering knowledge meant that the customer had access to the very best technical support. As a result, a cost-effective and efficient solution was provided to the refinery, ensuring that it could deliver increased fuel supply while also safeguarding availability.
The old diesel drives and steam turbines were replaced with new electric motors and gearboxes to deliver the desired speed increase.
32 December/January 2023 Irish Manufacturing Sulzer
www.sulzer.com
www.irish-manufacturing.com
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