1. Knowledge Sharing: GSP Pump Energy Assessment
Reduce opex

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

3. Knowledge sharing at ptt tank

4. Cost of pump life time

5. 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

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

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

8. 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)
P-001
Lean solvent booster pump
BB2 1
990
364.59
P-001
P-003
Rich solvent pump
365.54
P-003
3208-P-002
Hot oil circulation pump
1490
1672
X-01A, B, R
Expansion Turbine
BB1
3000
1729
X-01A, B, R

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

10. Case I: Modify impeller (Trim to minimum diameter)

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

12. Case I: Modify impeller (Trim to minimum diameter)
P-003M, R Rich Solvent Pump
Type: BB2
RPM: 990
Motor
Power: 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

13. Trim Impeller Information 3201-1/2-P-03M, R
In case that the head is enough for process.
Old Design
Design
1970
m3/hr
Design 53 m
Design
475.10 kW
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
Design
m3/hr
Design
44.67 m
Design
367.59 kW
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× ×𝑃𝑢𝑚𝑝 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

14. CASE II: optimize the operate unit

15. Expansion turbine esp (Achieved)

16. 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

17. 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

18. 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

19. 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

20. 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
฿ ,623.09
Baht/hr
Run 1 Unit
2,534.90
฿ ,038.20
Potential Saving if run Turbine 1 Unit
ปริมาณไฟฟ้าที่ประหยัดได้/ชั่วโมง
147.70
ค่าไฟฟ้าที่ประหยัดได้/ชั่วโมง ฿
ค่าไฟฟ้าที่ประหยัดได้/วัน
฿ 14,037.36
Baht/day
ค่าไฟฟ้าที่ประหยัดได้/เดือน
฿ 421,
Baht/month
ค่าไฟฟ้าที่ประหยัดได้/ปี
฿ 5,053,449.60
Baht/year

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

22. 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

23. 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

24. 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

25. 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
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

26. Case III: Alternative option

27. 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)

28. 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 Amp to 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%