Improvement Solutions
Raising Pump Efficiency Levels
The largest contributor to the cost of running a pump is the energy that it consumes. So, any factor that has the potential to lower the pump’s operational efficiency will push running costs upward.
There are numerous different reasons why pumps may run less efficiently than they should, which can significantly increase the associated energy costs. Here are some examples that you should be aware of:
- A change in process parameters or operational conditions (such as heightened throughput or increased exposure to vibrational forces).
- Alternations in the ambient surroundings in which the pump operates (subjecting the pump to higher temperatures, increased humidity levels, etc.).
- General wear over time. This can be influenced by the duty cycle of the pump, presence of contaminants in the fluid and numerous other variables.
- A change to the properties of the fluid being pumped (such as increased viscosity).
Celeros Flow Technology has access to sophisticated analysis tools, which make it possible to accurately estimate the effectiveness of prospective improvements. This allows different upgrade scenarios to be investigated prior to investment. These analysis tools can not only be applied to our own equipment, but third party equipment too. Such an evaluation can lead to marked efficiency improvements – helping to reduce day-to-day running costs and extending operational lifespan. The return on investment here is very short - in many cases just taking a few months to pay for itself.
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Improvement Solutions
Material Upgrades to Prolong Pump Usage
Universally recognized as one of the world’s foremost pump manufacturers, Celeros Flow Technology are responsible for many thousands of units deployed globally, across hundreds of different applications. As a result, we are uniquely positioned to advisese on potential metallurgy upgrades, with the objective of ensuring that the operational longevity of the equipment involved is maximized.
Case study example:
Excessive erosion on a KSMK pump in an oil extraction plant was having a negative impact on Mean Time Between Failures (MTBF). The pump had been in operation for less than 4 years but was demonstrating signs of excessive wear. ClydeUnion Pumps proposed a triple solution to upgrade the existing BB2 pump, including the application of advanced tungsten carbide coatings to mitigate erosion. Compared to expensive equipment replacement, our solution delivered cost savings for the customer, and the increase in reliability means that maintenance costs and downtime have also reduced.
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Improvement Solutions
Rapid Parts Supply to Minimize Downtime
Celeros Flow Technology’s pump brands are able to respond to parts enquiries promptly. We leverage a combination of OEM facilities and our network of service centers, plus global supply chain resources, to ensure our customers’ needs are met. Not only can genuine replacement parts be sourced quickly, but proprietary features have also been integrated which allow these parts to be installed in an extremely short period of time, and without the need for specialist torquing equipment.
Improvement Solutions
Hydraulic Re-Design to Address Process Changes
Essential to any pump’s operation is its hydraulic performance. This is measured in flow, pressure and power consumed. Celeros Flow Technology’s unrivalled technical expertise means that we are able to re-design any installed unit in order to optimize its operational requirements. In the majority of cases, this can be done by finding an alternative hydraulic setup that already exists (taken from the extensive portfolio of legacy designs we have available). We can also supply fully optimized clean sheet designs, using the latest software tools, if required.
Case study example:
Our US oil & gas customer required a hydraulic re-rate of a third-party multi-stage pump to new hydraulic conditions whilst maximizing efficiency. We identified that the most cost-effective means was to trim the impellers to match the desired flow and restore running clearances back to API 610 standards. The hydraulic re-rate achieved a 20% reduction in operating costs, a 30% reduction in energy consumption and an ROI in little more than 12 months.
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