your partner for hydraulic power recovery - sulzer
Post on 17-Nov-2021
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The Sulzer Advantage
Sulzer has years of experience applying reverse running pumps as power recovery turbines. Hundreds of Sulzer Hydraulic Power Recovery Turbines (HPRTs) are installed in refining hydrotreaters, gas processing and nitrogenous fertilizer plants - around the world.
Expertise Applications
The Right Product
• Inseveralindustrialprocesses,afluidunderhighpressuremustbethrottledtosuitsubsequentprocesssteps.Typically,conventionalpressurereducingvalvesareusedtodissipate,andconsequentlywastethishydraulicenergy.
• HydraulicPowerRecoveryTurbines(HPRTs)canconverttheexcesspressureintomechanicalshaftenergyandincreasetheoverallprocessefficiency.However,savingenergyisnotonlyaneconomicaspect;acarefuluseofresourcesisalsoanimportantcontributiontoenvironmentalprotection.
HPRTscanbefoundinthefollowingapplications:• Capture800kWto1.6MWofenergyinfertilizerplants
• Capture800kWinpowerrecoveryinrefininghydrotreaters
• Capture600kWingasprocessingplants
• Hydraulicturbinescomeinvariousshapesandsizes.Forhigherflowscommoninprocessstreams,centrifu-galpumpsinreverserotationareef-ficientlyusedasHPRTs.Forhighflowsandlowerpressuredifferential,mixedflow,oraxialflow(propeller)typeverti-calpumpsmaybeusedasHPRTs
• Sulzerhastherightproductstosup-portyourpumpingandHPRTneeds
Taking on Your Challenges
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Whatever the Process, We Have the Pumping Solutions
You set out the challenge, we present the solutions.
A gas-scrubbing HPRT application can recover more than 2 MW
Startuppump
Startupmotor
Level controllerBypass
Sour gas
Lean amine stream
Sweet gas stream
Am
ine
cont
acto
r
Str
ippe
r
Pump Motor
Clu
tch
HPRT
TheHPRTmaybeusedtodriveapump,generator,compressororotherrotatingmachinery.Speedisgov-ernedbytheinletcontrolvalve, motororgeneratorandtheelectricalgridfrequency.Ifrequired,aone-wayclutchbetweenamotorandtheHPRTpreventstheHPRTfromrobbingpowerfromthetrainunderlowflowstartupconditions. Duetohighgasvolumefractioncarryover,experiencestronglyindicatesthatconservativespeedsareprudenton Pump-Motor-HPRTtrainsinfertilizerplants.
Typical Hydraulic Turbine Installations
Splitrangeliquidlevelcontrollersaretypicallyusedtoregulateturbines.Thecontrolleradjuststhe HPRTinletvalveor furtheropenthebypassvalvewhentheturbineisoverpowered.
Overspeedtripdevicesareoftenfurnishedwithhydraulicturbines.Thisdevice shutstheHPRTinletvalveandacti-vatesoverspeedalarmswhenrequired.
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Pump and HPRT Products
KEY CUSTOMER BENEFITS
BBSradiallysplit,1and2stagepumpsareprimarilyusedinprocessapplicationsinrefineriesandpetrochemicalplants.TheBBSdoublesuctionimpellerisparticularlysuitedtolowNetPositiveSuctionHeadAvailable(NPSHA)applications.LiketheHSBabove,theycanbeutilizedtocaptureenergyasanHPRT.
APPLICATIONS
• Boosteraswellashighspeedcrudeshippingservices
• Sulfateremoval• ProcessHPRT
KEY CHARACTERISTICS
Capacities Upto4,200m3/h/22,000USgpmHeads Upto350m/1,500ftPressures Upto51bar/740psiTemperatures Upto425°C/800°F
BBS, CD AND HZB RADIALLY SPLIT SINGLE STAGE PUMPS ISO 13709 / API 610 BB2
BB2
BB1
KEY CUSTOMER BENEFITS
WhenrunbackwardsandreconfiguredasanHPRT,theHT-HSBorHSTisaeconomicalsolutiontoapressurereducingapplication.Theyareoneoftheworld’smostpopularnitrogenousfertilizerplantHPRTs.
APPLICATIONS
• Crudeoilpipelines• Heavydutyauxiliaryapplications
• FertilizerHPRTs
HSB HORIZONTAL AXIALLY SPLIT SINGLE STAGE BETWEEN BEARING PUMP ISO 13709 / API 610 BB1
KEY CHARACTERISTICS
Capacities Upto10,00m3/h/45,000USgpmHeads Upto550m/1,800ftPressures Upto150bar/2,200psiTemperatures Upto205°C/400°F
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KEY CUSTOMER BENEFITS
BBT/BBT-D1and2stagepumpsareprimarilyusedinprocessapplicationsinrefineriesandpetrochemicalplants.TheBBT-DdoublesuctionimpellerisparticularlysuitedtolowNPSHAapplications.BoththeBBTandBBT-DmaybeutilizedasHPRTs.
BBT/BBT-D AND CD 2-STAGE RADIALLY SPLIT PUMPS ISO 13709 / API 610 BB2
KEY CHARACTERISTICS
Capacities Upto2,300m3/h/10,000USgpmHeads Upto760m/2,500ftPressures Upto100bar/1,440psiTemperatures Upto425°C/800°F
APPLICATIONS
• Seawaterandcrudeoilboostingapplications
• ProcessHPRT
KEY CUSTOMER BENEFITS
MSD/MSD2/MSD-ROaredoublevoluteopposedimpellerpumpsusedinrefinerycharge,highpressureReverseOsmosis(RO),LiquefiedPetroleumGas(LPG)andrefinedproductpipelines.Over10,000areinstalled.SomeareusedasHPRTsinamineunitsandhydrotreaters.
KEY CHARACTERISTICS
Capacities Upto3,200m3/h/14,000USgpmHeads Upto2,900m/9,500ftPressures Upto300bar/4,400psiTemperatures Upto200°C/400°F
MSD, MSD2 AND MSD-RO AXIALLY SPLIT MULTISTAGE PUMPS ISO 13709 / API 610 BB3
APPLICATIONS
• Pipelines• Waterinjection• CO2pipelineandinjection• HPRTs
BB3
6
KEY CUSTOMER BENEFITS
SJD(API)processpumpsarespecifiedwhereverlimitedNPSHisavailable,eitherduetosystemconstraintsorliquidsoperatingneartheirvaporpressure.Typicalapplicationsincludeliquefiedpetroleumgasboosterandcryogenics.TheycanbeusedasHPRTsaswell.
SJD VERTICALLY SUSPENDED PROCESS PUMP ISO 13709 / API 610 VS6
KEY CHARACTERISTICS
Capacities Upto3,800m3/h/20,000USgpmHeads Upto700m/3,000ftPressures Upto75bar/1,100psiTemperatures Upto205°C/400°F
APPLICATIONS
• Shippingofliquefiedpetroleumgas(LPG)
• Crudeoilpipelinebooster• Debutanizer/depropanizerservicesincryogenicgasplants
KEY CUSTOMER BENEFITS
CPvolutestylepumpsareusedinbothoilproductionandhightemperaturerefineryapplications.Theyareparticularlysuitedtolowspecificgravityapplicationswheretheback-to-backdesignandcenterbushprovidenaturalaxialbalanceandadditionalshaftsupport.TheyalsomakeexcellentHPRTsforhighpressureletdownservices.
CP HORIZONTAL RADIALLY SPLIT MULTISTAGE BARREL PUMP ISO 13709 / API 610 BB5
KEY CHARACTERISTICS
Capacities Upto1,000m3/h/4,400USgpmHeads Upto7,000m/23,000ftPressures Upto425bar/6,250psiTemperatures Upto425°C/800°F
APPLICATIONS
• Highpressureoiltransport• Onshorewaterinjection• Offshorecrudeoilshipping• ProcessHPRTs
KEY CUSTOMER BENEFITS
GSGradiallysplitpumpsareusedinoilproduction,refiningandboilerfeedapplications.Theyareavailableinbothinlineandback-to-backrotorconfigurations.TheGSGback-to-backpumpsmakeexcellentHPRTsforhighpressureletdownprocessapplications.
APPLICATIONS
• Onshoreoroffshorewaterinjection
• Offshorecrudeoilshipping• ProcessHPRTs
KEY CHARACTERISTICS
Capacities Upto900m3/h/4,600USgpmHeads Upto2,600m/10,000ftPressures Upto300bar/4,500psiTemperatures Upto425°C/800°F
GSG DIFFUSER STYLE BARREL PUMP ISO 13709 / API 610 BB5
BB5
VS
7
References
Hydrotreater Charge Pump with the HPRT (China)
MSD-D 3 Stage Double Suction Pump with a HT-HSB Single Stage HPRT (USA)
CHALLENGES
Aseparateboosterpumpisinstalledonthepumpskidtoincreasethepressureofthe
availablequenchoilforPlan32from12barto40bar.Duetosafetyconcerns,mechanical
sealsandsealsystemstaticpressuredesignedtopumpandHPRTMaximumAllowable
WorkingPressure(MAWP)andMaximumAllowableWorkingTemperature(MAWT).
SOLUTION
HPRTtrain:pumpwithAPI682plans23&52,doubleextendedshaftmotor,over-running
clutch,andHPRTwithplans32and53C.API614lubesystemsuppliesentiretrain.
CHALLENGES
CO2flashesoutofsolutionaspressureisreducedthroughHPRT,andwhenexcited
throughpump.Resultingshockloadscanincreasemaintenancecosts.
SOLUTION
SelectsealsystemtoisolatesealfacesfromCO2.Useheavydutyshaftforrotorrigidity.
SelectlargerpumpandHPRTatreducedspeed.
PRODUCTS
Pump GSG150-360/6+6,MAWP260bar
MAWT318°C
HPRT GSG100-300/6+6,MAWP176bar
MAWT400°C
Pump/motor/HPRTskidisnearly12mlongx3mwide
andweighsnearly40tonnes
PRODUCTS
Pump 16x18x26MSD-D3stage
HPRT 16x18x27HT-HSB
CUSTOMER BENEFITS
• HPRTconvertspressureinto631KWshaftpowerandincreasestheoverallprocessefficiency
CUSTOMER BENEFITS
• HPRTconvertspressuredropinto1,600KWofshaftpowerandincreasestheoverallprocessefficiency
E10141en6.2014,Copyright©SulzerThisbrochureisageneralproductpresentation.Itdoesnotprovideawarrantyorguaranteeofanykind.Please,contactusforadescriptionofthewarrantiesandguaranteesofferedwithourproducts.Directionsforuseandsafetywillbegivenseparately.Allinformationhereinissubjecttochangewithoutnotice.
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