November 13, 2024
A refinery in the USA faced significant challenges with its cooling water system, experiencing reliability issues, excessive downtime, and costly repairs amounting to $105,000. By using SINET Fluid Flow, the refinery was able to determine a new pump configuration that not only increased system reliability but also saved $180,000 per year in energy costs and reduced CO₂ emissions by optimizing energy usage in the system.
Industry: Oil & Gas
Application: Refinery Cooling Water System
Region: USA
Challenge Overview:
The refinery, located in the Midwest USA, was dealing with several operational challenges related to its cooling water pumps:
- Premature erosion at the suction bell of a high-performing pump, reducing the equipment’s life and efficiency.
- Unscheduled downtime and repair costs totaling $105,000, caused by mechanical failures and high vibrations.
- A significant reduction in operational confidence due to recurring reliability issues, which raised concerns about the system’s sustainability and the environmental impact of inefficient pump operation.
The refinery’s team was tasked with solving the issues of premature erosion, improving system reliability, and reducing both operational and environmental costs.
Solution: SINET Fluid Flow Modeling and Optimization:
To solve these challenges, the team leveraged SINET Fluid Flow, a powerful tool for fluid system simulation and optimization. The solution followed these steps:
- Data Collection: Wireless sensors were deployed across the cooling system to capture flow, pressure, and temperature data in real-time. This data provided critical insights into the system's inefficiencies and performance.
- Modeling & Simulation:Using SINET Fluid Flow, the team created a detailed hydraulic model of the cooling water system. The software’s advanced simulation capabilities allowed the team to simulate various operating scenarios and accurately assess the system’s behavior under different conditions.
- Scenario Optimization: The team tested several configurations and operating conditions within SINET Fluid Flow to identify the most energy-efficient and environmentally sustainable configuration that would still meet the cooling requirements of the refinery.
- Implementation & Adjustments:With the optimal configuration identified, the team implemented the changes, adjusting pump operations and system flow patterns. SINET Fluid Flow's ability to test and refine these changes in a virtual environment helped reduce the risk of failure and ensured that the changes were both effective and cost-efficient.
Results:
- Improved Pump Configuration: By utilizing SINET Fluid Flow’s simulations, the team determined that the cooling system could meet operational needs with four pumps instead of six. This reduction in pump usage significantly cut energy consumption.
- Energy Savings:The optimized configuration resulted in $180,000 in annual energy savings, as fewer pumps were required to operate while still meeting the cooling needs of the refinery.
- Reduction in CO₂ Emissions:By reducing the number of pumps in operation, the refinery decreased its energy consumption, which directly led to a reduction in CO₂ emissions. This decrease was equivalent to removing approximately 2,364 metric tons of CO₂ from the atmosphere annually. This is roughly the same amount of CO₂ emitted by 500 passenger cars driven for one year, demonstrating a significant environmental benefit.
- Increased Reliability:The changes also improved system reliability by reducing wear and tear on the pumps and minimizing issues like premature suction bell erosion. This led to fewer mechanical failures and extended the life of the equipment.
- Reduced Maintenance Costs: With fewer breakdowns and better system performance, the refinery saw a reduction in maintenance costs. The refinery avoided $50,000 in repair and maintenance costs annually due to the improved system performance.
Key Benefits:
- $180,000 in Annual Energy Savings:Optimizing the pump configuration and reducing energy consumption resulted in significant cost savings.
- 2,364 Metric Tons of CO₂ Reduced Annually: The optimization helped reduce the refinery's carbon footprint by cutting down energy use and lowering emissions, contributing to a more sustainable operation.
- $50,000 in Avoided Maintenance Costs:With fewer mechanical failures and reduced system wear, maintenance costs were significantly reduced.
- Increased Equipment Lifespan and Reliability:The optimized system is more reliable, with reduced risk of pump failure and longer equipment lifespan.
SINET Fluid Flow's Role in the Solution:
SINET Fluid Flow was instrumental in the optimization process, providing the team with the necessary tools to model, simulate, and optimize the cooling water system with precision. The software’s ability to simulate various scenarios and predict system behavior allowed the team to test configurations virtually, minimizing the risk of costly mistakes and ensuring the most energy-efficient solution was implemented.
Conclusion:
By using SINET Fluid Flow, the refinery was able to optimize its cooling water pump configuration, resulting in $180,000 in annual energy savings, a reduction of 2,364 metric tons of CO₂ emissions annually, and improved system reliability. The transition from six pumps to four not only saved on energy costs but also reduced the environmental impact of the refinery’s operations. Additionally, the refinery avoided $50,000 in maintenance costs, demonstrating the significant financial and environmental benefits of this optimization.
This case highlights the power of advanced fluid system simulation tools like SINET Fluid Flow to drive both economic and environmental improvements in industrial operations, making it a key solution for sustainability in the oil and gas sector.
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