Chemical Engineering March 2020 - 34

Feature Report
Part 1
Updating Legacy
Rotating Equipment
A brief look at the benefits of installing modern materials and design upgrades
through retrofit projects in chemical plants
Pharic Smith
Sulzer Pumps (UK)
IN BRIEF
OPTIMIZING UPTIME
COST EFFECTIVE
SOLUTIONS
BOILER FEED PUMPS
COMPRESSORS
MODELING
IMPROVEMENTS
HOT GAS EXPANDERS
IMPROVED BLADE
PERFORMANCE
GAS TURBINES
MEETING NEW
STANDARDS
REAPING THE BENEFITS
M
odern chemical
manufacturing
plants depend on
the reliable operation
of numerous important assets
to maintain productivity.
Retaining legacy equipment is a
cost-effective way to minimize
capital expenditure, provided
efficiency and reliability can be
upheld. The implementation of
retrofit projects allows modern
materials and parts manufacturing
techniques to update
existing components extending
the asset's service life.
In many cases rotating equipFIGURE
1. Spare compressor rotors can be exchanged quickly to minimize
downtime
ment, such as steam turbines, generators,
pumps, compressors and expanders, make
up an important part of the production process.
Through continued use, components
wear and clearances increase, leading to
reduced efficiency. At the same time, processes
change and greater
productivity
may be expected from the legacy equipment.
Tackling these challenges successfully
can reduce operating costs and improve
reliability.
Optimizing uptime
The chemical manufacturing sector offers
many challenges, not least of which is the
operational
environment - working with
corrosive materials as well as steam can
increase the pressure on the maintenance
team. Working with equipment that has been
in service for many years, especially when
there is no support available from the original
equipment manufacturer (OEM), means
alternative solutions have to be found when
repairs and upgrades are required.
Tight production schedules mean that
downtime has to be minimized, so using a
34
planned maintenance program is always
preferred to prevent unexpected failures that
can cause lost revenue. While on-site maintenance
teams are often well-versed in the
operation of the equipment - expert support
can reduce repair times and deliver costeffective
solutions for more complex repairs.
To maximize the original investment in
equipment, the service life needs to be
extended as far as economically possible.
Retrofit projects offer the opportunity to upgrade
or replace components that can increase
performance through improved design
or materials.
Cost-effective solutions
Large-scale pumps are often cited for retrofit
projects because a life of continuous operation
can lead to wear of the impellers/rotors,
which reduces efficiency and increases running
costs. Those operating in the chemical
manufacturing industry may have to endure
a challenging working environment.
For example, nitric acid, which is an essential
raw material for the manufacture of
fertilizer, is created using inexpensive comCHEMICAL
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Chemical Engineering March 2020

Table of Contents for the Digital Edition of Chemical Engineering March 2020
