Knowledge Sharing: GSP Pump Energy Assessment Reduce opex

Senior Executive Vice President, Gas BU Natural Gas Processing EVP, Natural Gas Processing

Knowledge sharing at ptt tank

Cost of pump life time

Pump Performance Curve Abbreviations Head = Total head (in feet) developed at various flow rates EFF = Efficiency, ratio of output to input house power at various flow rates B.E.P. = Best efficiency point, point where operating head capacity coincides with maximum efficiency B.H.P. = Horse power required by the pump for any flow rates of the liquid with 1.0 Specific Gravity NPSHr = Net positive suction head required, energy required to overcome friction losses from the pump suction opening to the impeller vanes

Implication of running off the B.E.P. API610 Recommend operating range at 80% to 110% of BEP

What Is the benefit to run pump at bep? Energy saving Maintenance cost saving Improve Reliability of pump

Best practice from unido Energy mapping of the rotating equipment recommend: Power is greater than 100 kW Pump Tag Process Pump Type Stage RPM Motor Power (kW) 3201-1-P-001 Lean solvent booster pump BB2 1 990 364.59 3201-2-P-001 3201-1-P-003 Rich solvent pump 365.54 3201-2-P-003 3208-P-002 Hot oil circulation pump 1490 1672 3201-1-X-01A, B, R Expansion Turbine BB1 3000 1729 3201-2-X-01A, B, R

Actual Stable Flow (m3/hr) Percentage Difference Pump Tag Process Pump Type Rated Flow @ BEP (m3/hr) Actual Stable Flow (m3/hr) Percentage Difference 3201-1-P-001M, R Lean solvent booster pump BB2 2738 1820 66% 3201-2-P-001M, R 1840 67% 3201-1-P-003M, R Rich solvent pump 3750 1830 49% 3201-2-P-003M, R 1970 53% 3208-P-002A, B, C, R Hot oil circulation pump 5000 2700 54% 3201-1-X-01A, B, R Expansion Turbine BB1 1150 850 74% 3201-2-X-01A, B, R API610 Recommend operating range at 80% to 110% of BEP

Case I: Modify impeller (Trim to minimum diameter)

*Head (Pressure) must be enough!!! Case I: Modify impeller (Trim to minimum diameter) Example 3201-1-P-001M, R Lean solvent booster pump 3201-2-P-001M, R 3201-1-P-003M, R Rich solvent pump 3201-2-P-003M, R Smaller Impeller *Head (Pressure) must be enough!!! Recommend to establish Cross functional team from Operation, Process, Maintenance

Case I: Modify impeller (Trim to minimum diameter) 3201-2-P-003M, R Rich Solvent Pump Type: BB2 RPM: 990 Motor Power: 365.54 kw Volt: 11 kV Phase: 3 Hz: 50 Actual Data Flow: 1970 m3/hr Suction: 1.5 barg Discharge: 8 barg Pump SG: 1.052 Vapor Pressure: 2.28 Temp: 83 C Suction pressure: 2 barg Discharge Pressure: 7.3 barg Shutoff head: 58 m NPSHA: 7.56 m NPSHR: 4.3 m BEP head: 45 m BEP flow: 3750 m3/hr Eff: 0.85

Trim Impeller Information 3201-1/2-P-03M, R In case that the head is enough for process. Old Design   Flow@Old Design 1970 m3/hr Head@Old Design 53 m Power@Old Design 475.10 kW Diameter@Old Design 610 mm EFF 63% Diff pressure 5.47 Suction pressure 1.50 barg Discharge Pressure 6.97 Barg Q2 = D2 Q1 D1 H2 = (D2)2 H1 (D1)2 BHP2 = (D2)3 BHP1 (D1)3 New Design   Flow@New Design 1970.00 m3/hr Head@New Design 44.67 m Power@New Design 367.59 kW Diameter@New Design 560.00 mm EFF 69% Head drop 8.33 Power drop 107.51 Diff pressure 4.61 barg Suction pressure 1.50 Barg Discharge Pressure 6.11 Total saving 3,710,751.81 Baht/year 𝐵𝐾𝑊= 𝐹𝑙𝑜𝑤 𝑚 3 ℎ ×𝐻𝑒𝑎𝑑(𝑚)×𝑆𝐺×9.8 3600×𝑃𝑢𝑚𝑝 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

CASE II: optimize the operate unit

Expansion turbine esp (Achieved)

CASE II: optimize the operate unit (run 1 of 3) Previously run 2 of 3 3201-1/2-X-01A, B, R Expansion Turbine Total = 1,640 m3/hr 820 m3/hr 820 m3/hr Standby By Pass Valve A B R

CASE II: optimize the operate unit (run 1 of 3) Real Operating Condition Previously run 2 of 3 3201-1/2-X-01A, B, R Expansion Turbine Preferred Operating Region

CASE II: optimize the operate unit (run 1 of 3) Change run 1 of 3 3201-1/2-X-01A, B, R Expansion Turbine Total = 1,640 m3/hr 1,200 m3/hr Standby Standby By Pass Valve 440 m3/hr A B R

Vibration Comparison Increase By CASE II: optimize the operate unit (run 1 of 3) Change run 1 of 3 3201-1/2-X-01A, B, R Expansion Turbine Train Case Equipment Condition DE NDE % Valve Amp Motor (Ampere) LV003E Big LV003D Small X (mm.) Y (mm.) Z (mm.) Train#1 1 3201-1X-001A Full Load 1 Unit 0.02 0.015 0.016 0.019 0.35 75 62.64 166.31 15.7 27.8 3201-1X-001B Stop 103.67 2 Share Load 2 Units 0.03 0.024 30.5 88 176 25.2 0.032 0.018 0.17 Summary Case 2 compare with case 1 Vibration Comparison Increase By +50% +60% +25% +26% 0% - +9.69

Potential Saving if run Turbine 1 Unit CASE II: optimize the operate unit (run 1 of 3) Change run 1 of 3 3201-1/2-X-01A, B, R Expansion Turbine Run 2 Units ปริมาณไฟฟ้าที่ใช้/ชั่วโมง 2,682.60 kW/hr ค่าไฟฟ้า/ชั่วโมง ฿ 10,623.09 Baht/hr Run 1 Unit 2,534.90 ฿ 10,038.20 Potential Saving if run Turbine 1 Unit ปริมาณไฟฟ้าที่ประหยัดได้/ชั่วโมง 147.70 ค่าไฟฟ้าที่ประหยัดได้/ชั่วโมง ฿ 584.89 ค่าไฟฟ้าที่ประหยัดได้/วัน ฿ 14,037.36 Baht/day ค่าไฟฟ้าที่ประหยัดได้/เดือน ฿ 421,120 .80 Baht/month ค่าไฟฟ้าที่ประหยัดได้/ปี ฿ 5,053,449.60 Baht/year

Hot oil pump esp 3208-P-02A, B, C, R (Achieved)

Hot oil circulation pump CASE II: optimize the operate unit (run 2 of 4) Previously run 3 of 4 3208-P-002A, B, C, R Hot oil circulation pump Original Design Total = 12,000 m3/hr Hot oil AGRU E-04 Usage Reduction Total = 8,000 m3/hr 2670 m3/hr 2670 m3/hr 2670 m3/hr Standby A B C R

Hot oil circulation pump CASE II: optimize the operate unit (run 2 of 4) Previously run 3 of 4 3208-P-002A, B, C, R Hot oil circulation pump Real Operating Condition Preferred Operating Region

CASE II: optimize the operate unit (run 2 of 4) Change to run 2 of 4 3208-P-002A, B, C, R Hot oil circulation pump Total = 8,000 m3/hr 4000 m3/hr 4000 m3/hr Standby Standby A B C R

CASE II: optimize the operate unit (run 2 of 4) Change to run 2 of 4 3208-P-002A, B, C, R Hot oil circulation pump Pump Tag Process Actual (kW) Improved (kW) Save (kW) Electric cost (Baht/kWh) Save cost (Baht)/Year Investment (Baht) IRR Other Benefit 3208-P-002 ABCR Hot oil circulation pump 4372.56 3238.935 1133.627 3.94 39,126,464.48 - Increase Pump and Seal life Case Equipment Condition DE NDE Amp Motor (Ampere) X (mm.) Y (mm.) Z (mm.) 1 Before 3 units 0.030 0.024 0.146 270 (3 units) 2 After 2 Units 0.027 0.020 0.062 200 (2 units) Summary Vibration Comparison Reduce By -10% -16% -57% -70

Case III: Alternative option

Energy saving: Non-Metallic Wearing restoration A (Action) Approved by API682 edition 10th Advantages: REDUCE Clearance 50%. Reduce radial Hydraulic force. Reduce vibration Reduce re-circulation (increase efficiency)

Energy saving: Non-Metallic Wearing restoration R (Result) Results: REDUCE Clearance 50%. From 0.65 mm to 0.33 mm REDUCE Electricity Cost 5-11% Current reduce from 35.90 Amp to 33.80 Amp REDUCE = 2.10 Amp Energy cost = 30,000 Baht/year = 6% Financial Analysis Investment Cost: 120,000 Baht Weighted Average Cost Of Capital: 11.02% Internal Rate of Return: 20%