OFFSHORE PUMP RERATING:
Driving Efficiency and Sustainability
Project Overview
Trillium Flow Technologies recently completed a successful pump rerating project for a major offshore oil platform in the North Sea. This case study demonstrates our ability to provide innovative engineered solutions that enhance performance, reduce operational costs, and deliver environmental benefits.
Customer Challenge
The customer approached Trillium with the need to:
- Evaluate options to rerate an existing BB5 multi-stage main oil line (MOL) pump
- Adapt the pump to significantly changed duty requirements
- Maintain compatibility with existing infrastructure
New Operating Requirements
The changing operational profile of the platform required:
- 65% reduction in flow rate due to reduced export rates
- 12% reduction in generated head due to reduced export line pressure
- Retention of existing barrel casing and pipework
- Continued use of the existing fixed-speed motor
The Trillium Solution
Our approach incorporated a comprehensive engineering process:
1. Advanced Hydraulic Design
- Developed new hydraulics specifically tailored to the revised operating conditions
- Employed Computational Fluid Dynamics (CFD) analysis to confirm performance predictions
- Optimized impeller and diffuser designs for maximum efficiency at the new duty point
2. Meticulous Mechanical Engineering
- Conducted detailed mechanical layout and build verification of new/existing components
- Performed comprehensive rotor dynamic studies to ensure reliable operation
- Engineered components to fit within the existing pressure boundary components
3. Rigorous Performance Testing
- Conducted hydraulic and mechanical verification testing at Trillium’s specialized facility
- Confirmed performance curves matched design predictions
- Validated mechanical reliability under various operating conditions
Performance Improvements
The re-rated pump delivered remarkable improvements compared to operating the original pump at the new flow conditions:
Customer Benefits
The re-rating project delivered significant operational and environmental advantages:
Economic Benefits
- Energy savings of 10.5 GWh per year, translating to approximately $2.4 million in annual cost reduction
- Increased equipment availability due to improved Mean Time Between Failures (MTBF)
- Extended asset lifecycle of existing equipment, avoiding capital expenditure on replacement
Environmental Impact
- CO₂ emissions reduction of 4,400 tonnes per year
- Lower environmental footprint from reduced energy consumption
- Alignment with sustainability goals while maintaining production capabilities
Engineering Expertise Demonstrated
- This project highlights Trillium Flow Technologies’ capabilities in:
- Advanced hydraulic design and optimization
- Computational analysis and simulation
- Retrofit engineering within existing constraints
- Performance testing and validation
- Sustainability-focused engineering solutions
Conclusion
The successful completion of this pump re-rating project demonstrates Trillium’s ability to deliver engineered solutions that address the evolving needs of offshore operations. By optimizing existing equipment for new duty conditions, we helped our customer achieve significant cost savings, improved reliability, and reduced environmental impact—all without the need for major capital investment.
This project exemplifies our commitment to being a full lifecycle partner, providing innovative solutions that add value throughout the entire operational life of pumping systems.
Contact Us
For more information about our capabilities in FLNG and offshore applications, please contact your Trillium representative or click here to contact us and have your inquiry immediately routed to our sales team.
