Sulzer Ag · SIX:SUN
Sulzer — Investor Presentation (March 2013)
41 slides from Sulzer's investor presentation, March 2013
Slide 1: HPcp Barrel Casing Pumps
HPcp Barrel Casing Pumps Sulzer Pumps The Heart of Your Process
Slide 2: HPcp Designation & Description
HPcp Designation & Description Sulzer Pumps API type BB5 Between bearings, multistage, radially split, double casing. Sulzer designation HPcp xxx - yyy - n stages Number of stages Nominal impeller diameter. mm. Discharge branch diameter. mm. • HPcp is a diffuser design, full pull-out cartridge b
Slide 3: Main applications
HPcp Main applications Sulzer Pumps Seawater & Produced Water Injection Oil Export Pipeline MyPresentation <Copyright © Sulzer Pumps> | slide 3
Slide 4: Range coverage
HPcp Range coverage Sulzer Pumps 6000 Thunder Horse 5000 Holstein Azeri C&WP 4000 Head (m) 3000 2000 1000 0 0 1000 2000 3000 4000 Flow (m3/h) back to back, bolted delivery cover installed pumps in-line, bolted delivery cover in-line, twist lock delivery cover MyPresentation <Copyright © Sulzer Pumps
Slide 5: Design Features – Hydraulics
HPcp Design Features – Hydraulics Sulzer Pumps Well proven hydraulics in the NQ 13 to 36 range. Reliable suction performance backed up by life warranties if required – Sulzer were the first pump company to give 40,000 hour guarantees on suction impellers. Swirl break technology aids rotor stab
Slide 6: Design Features – Hydraulics
HPcp Design Features – Hydraulics Sulzer Pumps Thick shrouds provide high strength for high head duties Natural frequency away from resonance thus avoiding shroud breakage Continuous channel diffuser gives high efficiency Precision castings give high efficiency and low hydraulic unbalance My
Slide 7: Design Features – Rotor Construction
HPcp Design Features – Rotor Construction Sulzer Pumps Shrink fit impellers driven by double keys and located by titanium thrust rings Hydraulic fit balance piston Hydraulic fit thrust collar Absence of threads eliminates stress raisers Component balance to ISO grade 1.0 and check rotor ba
Slide 8: Design Features – Rotor Construction
HPcp Design Features – Rotor Construction Sulzer Pumps Back to back design naturally balances axial thrust reducing bearing size Differential pressure across bushes reduced to 50% of full pressure Case cover only sees 50% discharge pressure Centre bush acts as a support allowing 8 stage+ con
Slide 9: Design Features – Rotor Construction
HPcp Design Features – Rotor Construction Sulzer Pumps Center bush on back to back layout acts as a product lubricated bearing controlling shaft deflection and reducing vibration MyPresentation <Copyright © Sulzer Pumps> | slide 9
Slide 10: Design Features – Bearings
HPcp Design Features – Bearings Sulzer Pumps 4 lobe arc journal bearings. 8 pad center pivoted thrust bearings, these may be specified to accommodate thrust loads in either direction if required. A self contained design not requiring a separate oil system is available for smaller size pumps.
Slide 11: Design Features – Main Connections
HPcp Design Features – Main Connections Sulzer Pumps The three main alternatives are Flange, traditional ANSI standard bolted flange. Heavy (expensive) and space consuming Pad, studded pad on the pump casing to accept a standard ANSI flange being bolted to it. Light but still requires a flange t
Slide 12: Design Features – Flange Connections
HPcp Design Features – Flange Connections Sulzer Pumps MyPresentation <Copyright © Sulzer Pumps> | slide 12
Slide 13: Design Features – Pad Connections
HPcp Design Features – Pad Connections Sulzer Pumps MyPresentation <Copyright © Sulzer Pumps> | slide 13
Slide 14: Design Features – Techloc Connections
HPcp Design Features – Techloc Connections Sulzer Pumps MyPresentation <Copyright © Sulzer Pumps> | slide 14
Slide 15: Materials
HPcp Design Features – Materials Sulzer Pumps Standard Materials Duplex or Super Duplex construction throughout. Stellite overlay on all internal wear parts Enhanced wear parts for Produced Water and other abrasive applications SUME®PUMP SA 30 3rd generation coating on all wear parts Wear res
Slide 16: Pressure Containment
HPcp Pressure Containment Sulzer Pumps Sulzer has developed advanced,well proven 3D FEA tools Basic 3D model Deformation in operation Casing/cover contact on hydro-test MyPresentation <Copyright © Sulzer Pumps> | slide 16
Slide 17: Full cartridge design
HPcp Full cartridge design Sulzer Pumps Advantage Quick and safe cartridge change including bearings and seals as a complete unit Step 1 Suspended and supported on rollers at DE Step 2 Supported for re-rigging Step 3 Final installation MyPresentation <Copyright © Sulzer Pumps> | slide 17
Slide 18: Options: Twistlock Cover, In Line Construction
HPcp Options Twistlock Cover, In Line Construction Sulzer Pumps In-line impeller arrangement with dry twist lock closure for up to 8 stages and design pressures below ~400 bar MyPresentation <Copyright © Sulzer Pumps> | slide 18
Slide 19: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps No heavy bolting required. Suitable for operation up to 400 bar depending on pump size. Minimizes barrel size (no heavy bolts to be accommodated). Minimizes cartridge size (no cover flange. Cartridge change out within a single shift. MyP
Slide 20: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Cartridge assembled and ready for fitting. Initial line-up to the barrel. MyPresentation <Copyright © Sulzer Pumps> | slide 20
Slide 21: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Cartridge teeth turned to align with the slots in the barrel. Cartridge is then inserted into the barrel. MyPresentation <Copyright © Sulzer Pumps> | slide 21
Slide 22: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Suction end retaining plates ready for fitting. MyPresentation <Copyright © Sulzer Pumps> | slide 22
Slide 23: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Suction end retaining plates being fitted to lock the cartridge from the suction end. MyPresentation <Copyright © Sulzer Pumps> | slide 23
Slide 24: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps The suction end is now assembled, work now commences at the discharge end. MyPresentation <Copyright © Sulzer Pumps> | slide 24
Slide 25: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps The cartridge end block is now rotated to lock the teeth into position. MyPresentation <Copyright © Sulzer Pumps> | slide 25
Slide 26: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Discharge end retaining screws are now fixed in place. The cartridge is now locked from the suction and discharge end of the barrel. MyPresentation <Copyright © Sulzer Pumps> | slide 26
Slide 27: Design Features – Twistlock System
HPcp Design Features – Twistlock System Sulzer Pumps Assembly is now complete and the pump ready to be put into service. MyPresentation <Copyright © Sulzer Pumps> | slide 27
Slide 28: Twistlock – Full Sequence
HPcp Twistlock – Full Sequence Sulzer Pumps MyPresentation <Copyright © Sulzer Pumps> | slide 28
Slide 29: Twistlock cartridges and barrel
HPcp Design Features – Twistlock System Sulzer Pumps Twistlock cartridges and barrel MyPresentation <Copyright © Sulzer Pumps> | slide 29
Slide 30: Options: Bolted Cover, In Line Construction
HPcp Options Bolted Cover, In Line Construction Sulzer Pumps Inline impeller arrangement with bolted delivery cover for up to 8 stages and design pressure above ~400 bar MyPresentation <Copyright © Sulzer Pumps> | slide 30
Slide 31: Options: Bolted Cover, Back to Back Construction
HPcp Options Bolted Cover, Back to Back Construction Sulzer Pumps Back to back impeller arrangement with bolted delivery cover for more than 8 stages MyPresentation <Copyright © Sulzer Pumps> | slide 31
Slide 32: Design Features – Bolted End Cover
HPcp Design Features – Bolted End Cover Sulzer Pumps Bolted design for pressures above 400 bar depending on pump size. Casing cover seal leakage instrumentation available. Worlds highest pressure centrifugal injection pump built using this layout (606 bar operating pressure, 909 bar test press
Slide 33: Design Features – Superbolt Nut
HPcp Design Features – Superbolt Nut Sulzer Pumps Superbolt Nut Proven design No heavy hydraulic jack required No special tools required Smaller barrel casing OD MyPresentation <Copyright © Sulzer Pumps> | slide 33
Slide 34: Finite Element Analysis - Suction Casing
HPcp Finite Element Analysis - Suction Casing Sulzer Pumps Hydrotest Equivalent Stress MyPresentation <Copyright © Sulzer Pumps> | slide 34
Slide 35: Cartridge Types
HPcp Design Features – Cartridge Types Sulzer Pumps Cartridge with bolted end cover MyPresentation <Copyright © Sulzer Pumps> | slide 35
Slide 36: Proven Performance
HPcp Proven Performance Sulzer Pumps Physically testing pumps under all conditions verifies the correlation between theoretical and actual rotor dynamic behaviour New Condition Worn Condition Thunder Horse 2 X new clearances Shaft Displacement DE NDE DE NDE Calculated 1.9 5.8 4.5 5.5 (Microns Pk)
Slide 37: Wear mechanisms - flow velocities
HPcp Wear mechanisms - flow velocities Sulzer Pumps B B A A A A Velocities B B A: high C B: medium to high C: high (90° impact, jet) MyPresentation <Copyright © Sulzer Pumps> | slide 37
Slide 38: Wear mechanisms - flow velocities
HPcp Wear mechanisms - flow velocities Sulzer Pumps Influencing factors Quality of pumped liquid, sea and/or produced water. Velocity of pumped liquid. – δ = constant * (1+10sin2ε) * csq,eq * w 3.4 * GSF * F Mat – where: – δ material loss rate [µm/h] – ε impact angle [°] – csq,eq equivalent qu
Slide 39: Material Testing – Erosion/corrosion test Rig
HPcp Material Testing – Erosion/corrosion test Rig Sulzer Pumps Rotor velocity up to 40 m/s 6 specimens in stator Corrosive media with solids Electro-chemical monitoring to determine transition points MyPresentation <Copyright © Sulzer Pumps> | slide 39
Slide 40: References
HPcp References Sulzer Pumps 1975. World’s first duplex injection pump. Sonatrach – Algeria – 13 units 1977. World’s largest injection pumps. Saudi Aramco - 15.7 MW - 2 units 1981. World’s largest injection pumps Sohio – Alaska – 18.8 MW – 2 units 1984. World’s Largest Offshore Injection Pum
Slide 41: References
HPcp References Sulzer Pumps Sulzer HPcp injection pumps >1,250 MW installed power. >120,000,000 operating hours >99% availability MyPresentation <Copyright © Sulzer Pumps> | slide 41