149.6
GWh
37450
Tons
18.8
MHow can you achieve decarbonization operation goals and reduce energy costs?
It can be difficult to pinpoint performance and inefficiency problems with every pump, valve, seal and actuator within each flow loop process across a refinery, chemical plant or other type of plant. The energy consumed by this equipment can be scattered across hundreds, if not thousands, of assets.
According to the Hydraulic Institute, because up to 50% of plant electricity is consumed by pumping systems, operators can benefit greatly by implementing a programmatic approach with a wide range of energy efficiency considerations — including process needs and control schemes.
Flowserve’s Energy Advantage Program is a holistic flow control approach aimed at helping operators reach their carbon reduction goals and lower total cost of ownership. It provides customers with Flowserve engineering expertise, a systematic data-driven evaluation process and a complete offering of products and services that can help increase energy efficiency through optimization of pump and valve power consumption, reduce carbon emissions, improve plant productivity and reliability, and provide operational cost savings.
Bespoke solutions engineered to match your ambition
Flowserve helps you identify opportunities within existing plants and process in the following areas:
- Greater Efficiency - Optimize energy consumption in pumping systems to achieve energy transition goals. Enable significant efficiency gains for pumps and valves and utilize power recovery turbines to convert waste energy for productive uses.
- Reduced Carbon - Minimize hydrocarbon fugitive emissions. Reduce environmental impact with seal and seal system upgrades, drivetrain electrification and flare gas recovery.
- Lower Total Cost of Ownership - Increase asset reliability and lower operational expenses. Improve equipment reliability and reduce maintenance spend with digital solutions that add predictive maintenance capabilities.
Quickly make sustainability impacts
The Energy Advantage Program incorporates the global engineering expertise of Flowserve with our innovative, data-driven optimization of flow loop operations.
Combined with the complete Flowserve offerings of superior fluid motion and control products and services, the Energy Advantage Program enables companies like yours to realize a significant return on investment in as quickly as 12 to 18 months.
Related Resources
Related Technical Articles
Related Technical Articles
Case studies from global companies
The Energy Advantage Program can be successfully applied across industries, flow-loop processes and applications to help your company realize measurable results in significantly reducing energy costs and fugitive emissions. Examples from Flowserve customers include the following:
The quantified sustainability impact benefits are as follows:
- Power consumption reduced by 2229 MWh per annum
- Reduced carbon footprint by 1339 metric ton per annum
- Financial benefit of €334,000 per annum
- Improved process control by upgrading from hand to automated control valves
Petroleum Refinery
Implementing the Energy Advantage Program to identify and act on energy improvement opportunities within the plant's flow loops.
Contact your Flowserve representative for full case study details.
The quantified sustainability impact benefits are as follows:
- Combined power consumption reduction by approximately 3810 MWh per annum
- Estimated annual savings from reduced energy consumption of $230,000
- Approximate CO2 savings of 2285 metric ton per annum
- Increased redundancy (5oo5 to 4oo5 operation)
- Increased reliability through higher NPSH 3% margin
Naptha Cracking
Implementing the Energy Advantage Program enabled flow loop analysis in a petrochemical plant to reduce energy consumption and carbon footprint.
The quantified sustainability impact benefits are as follows:
- Power consumption reduced by 11,000 MWh per annum
- Financial benefit €880,000 per annum
- CO2 saving 6000 metric ton per annum
- Increased reliability of pump and mechanical seal by operating close to BEP
- Increased reliability of control valves by reduced pressure drop
Midstream Crude Oil
Implementing the Energy Advantage Program enabled pump hydraulic upgrade to reduce energy and carbon footprint.
The quantified sustainability impact benefits are as follows:
- Power consumption reduction of approximately 10,200 MWh per annum
- Estimated financial benefit of €816,000 per annum
- Approximate CO2 savings of 6120 metric ton per annum
- Increased reliability through greater separation margin between operating speeds and rotor critical speeds
Coal-fired Power Plant
Implementing the Energy Advantage Program enabled energy optimization of a coal-fired power plant boiler feedwater system to reduce energy consumption and carbon footprint.
The quantified sustainability impact benefits are as follows:
- Combined power consumption reduced by 4249 MWh per annum
- Financial benefit of €255,000 per annum
- Reversible design installed in one day
- Increased reliability through operation near design point
- New back-pullout improves reliability
Nuclear
Implementing the Energy Advantage Program enabled pump hydraulic rerate to prevent significant energy waste.
The impact benefits are as follows:
- Improved the steelworks’ safety, ergonomics, and MTBR
- Reduced unplanned downtime, water, and chemical usage
The estimated annual savings/reductions are as follows:
- 7200 MWh power consumption
- 4320 metric ton of CO2 saving
- Electricity costs of $520,000
- OPEX of $292,000
Steelworks
Implementing the Energy Advantage Program enabled streamlining steelworks pump process to reduce carbon footprint and increase the bottom line.
Ideal systemic solutions
Pumps
Solutions available with the Energy Advantage Program can include the hydraulic re-rating of pumps or changing our existing pumps to new, high-performance models. Flowserve also can recommend modifications to existing equipment in order to improve efficiency by reducing clearances or replacing parts with coated components. For example, new conditions of service (COS) can be met using well-established pump rerate solutions. These include impeller trimming, de-staging, volute and diffuser modifications, drop-in replacement pumps, and bespoke hydraulic solutions such as re-designed impellers and stators.
As a result, customers can self-fund pump reliability initiatives with the money saved.
Valves
Your existing control valve equipment and utilization can be optimized. We can also evaluate and recommend ways to minimize control valve throttling. Our specialists analyze critical flow loops in your facility, including control valves, to gather data, devise and implement a contracting and execution model, and adjust and monitor resultant savings.
As a result, you can reduce the losses associated with valve throttling and bypass control changes and the hydraulic requirements on the pumps that feed your flow loops.
Drivetrains
Existing drivetrains can be replaced with high-efficiency models or adapted to fit variable frequency drives. We can help evaluate existing variable speed drives for additional savings with control scheme changes. Steam turbine and gearbox-driven pumps can also provide substantial savings with re-rate solutions that optimize the pump hydraulic output for the system.
Other options
You can upgrade or replace the current mechanical seals identified during our evaluation of flow loop processes. We help you reduce the energy input by matching equipment to new duty requirements and positioning the best efficiency point (BEP) as close as possible to the dominant operating condition. Additional solutions we can recommend to improve system efficiency include the use of power recovery turbines and energy recovery devices (ERDs). We also will help you implement ongoing monitoring to sustain the savings estimated through the Energy Advantage Program.
Schedule a discovery session
Contact Us