Modern pumping systems and precision control valves are revolutionizing how power generation facilities manage their critical fluid systems, delivering substantial energy savings, reduced emissions, and improved operational reliability.
Pumps and piping systems form the critical circulatory network of every power generation facility, quietly enabling the conversion of various energy sources into electricity that powers our modern world. From cooling water systems that maintain optimal operating temperatures to feedwater pumps that deliver precisely conditioned water to boilers and steam generators, these components are fundamental to plant efficiency, reliability, and safety.
While preventive maintenance forms the foundation of reliable pump operations, forward-thinking power generation facilities are increasingly focusing on efficiency optimization as a parallel strategy. Depending on the type of power facility, pumping systems often account for 25% or more of a typical plant’s auxiliary power consumption. Thus, even marginal efficiency improvements can yield substantial energy savings and operational cost reductions over time.
This dual focus on reliability and efficiency has sparked innovation in diagnostic and optimization technologies. Among these advancements, specialized pump efficiency improvement tools have emerged as powerful assets for engineering teams. These tools combine real-time performance monitoring with sophisticated analytical capabilities to identify inefficiencies, predict potential issues, and recommend precise optimization measures.
Pump Energy Optimization Service
Sulzer Services, a provider of parts as well as maintenance and repair solutions for pumps and other power plant equipment, recently launched a new pump energy optimization solution. Called the Sulzer Energy Optimization Service, the solution is touted to be an “energy efficiency and carbon reduction service that will create a new best practice standard for the operation of centrifugal pumps across their lifecycle.” The service is expected to benefit energy intensive industries including power generation.
“Inefficient and unreliable pumps cost operators in the industrial sectors millions of dollars in unnecessary downtime, energy costs, and carbon emissions every year,” said Ravin Pillay-Ramsamy, president of the Services division at Sulzer. “Sulzer Energy Optimization Service offers a comprehensive solution that tackles this inefficiency—from identification through to improvement and monitoring.”
In This Issue
Full issueThe service was launched to address what Sulzer called “growing demand for industrial energy efficiency.” It brings together digital analysis, machine learning, and ongoing monitoring with the company’s decades of engineering experience to “drive down carbon emissions, enhance reliability, and reduce energy costs.” Sulzer claims the efficiency of some pumps can be increased by as much as 30% with the service.
“A pilot customer in Spain will now save €1 million in energy costs and over 2,300 tonnes of carbon dioxide a year as a result of energy optimization improvements identified by the service,” Pillay-Ramsamy said. “By rerating five pumps, energy efficiency increased from 72% to 83%, saving the operator 5,000 MWh in electricity every year.”
There are effectively four steps involved in the process. An initial pump energy audit is conducted first (Figure 1). This is designed to identify areas of inefficiency. Sulzer’s proprietary calculator, called PumpWise, analyzes the energy, carbon, and monetary savings that could potentially be achieved.
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1. A pump energy audit helps plant managers understand how a facility’s pump assets are currently operating and the root cause of inefficiency. Courtesy: Sulzer |
A tailored proposal is then generated by the audit team, presenting a range of options that could be implemented. The goal of this step is to offer ideas that will ensure pumps operate at their best efficiency points. Examples of engineered retrofits that could be suggested include hydraulic re-rates, adding specialized coatings, and adjusting wear clearances, among other things.
Each option weighs operational costs, investment, downtime, payback, and efficiency guarantees. The upgrades are then implemented with support from Sulzer’s established retrofit team, which the company said has delivered more than 4,000 retrofit projects globally since its inception in 2010. The team is reportedly supported by a network of more than 120 service locations globally.
Post retrofit, Sulzer offers a performance agreement to maintain optimized reliability and efficiency. This includes access to Blue Box, the company’s proprietary machine learning technology that purportedly turns pump performance data into actionable insights.
“For operators who are constantly challenged to do more with less, making energy efficiency improvements is a win-win,” said Pillay-Ramsamy. “Altogether, we believe this solution creates a new best practice standard for pump operation that goes above and beyond in supporting operators to remain future-ready.”
Innovative Control Valve Design
While pump efficiency optimization tools provide crucial insights for system performance, translating these insights into operational reality requires precision control mechanisms. At the intersection of pumping systems and process control lies one of the most critical components in any power generation facility: the control valve.
Control valves serve as the final control elements that regulate flowrates, pressures, and fluid distribution throughout the plant. In essence, they are the executive arm of the control system, converting electrical signals into precise mechanical movements that directly impact process variables. Even the most sophisticated monitoring systems and efficiency algorithms cannot overcome the limitations of inadequate valve performance.
This critical dependence on valve precision has driven significant innovation in control valve design. Among these advancements, the v-port series control valve represents a notable evolution in flow control technology. By addressing common challenges in traditional valve designs—including imprecise throttling, susceptibility to cavitation, and inconsistent performance across varying process conditions—these valves enable the level of control accuracy necessary to fully realize the efficiency potential identified by modern diagnostic tools.
Aalberts integrated piping systems recently introduced a new product addition: the Apollo v-port series control valve (Figure 2). The Apollo v-port series control valve is designed for precise flow control, durability, reliability, and versatility across a range of applications and industries, including power generation and renewable energy. Key features of the Apollo v-port series include a three-piece construction with enclosed fasteners for easy maintenance and repair, standard-port and full-port options for versatility, and stainless-steel trim and hardware for corrosion resistance.
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2. The Apollo v-port ball valve is designed to handle higher fluid velocities and increased pressure drops when the valve is in partly open positions. Selecting a v-port ball valve for control operations may allow users to choose a more cost-effective and smaller diameter valve when compared to using more traditional control valves. Courtesy: Aalberts IPS |
The pressure-balanced solid ball reduces operating torque and ensures smoother operation, while compression-controlled spiral-wound gaskets improve sealing and reduce leakage. The anti-blowout one-piece bottom-entry stem enhances safety by preventing stem ejection under pressure, and the statically grounded ball, stem, and body reduce the risk of static electricity buildup.
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3. This graphic shows flow coefficient (Cv) curve profiles for Apollo 84B (carbon steel) and 85B (stainless steel) series control valves across the spectrum of degrees open. Courtesy: Aalberts IPS |
The Apollo v-port profile geometries were developed using computational fluid dynamics (CFD) studies. They were then validated with testing to create the valve flow coefficient (Cv) curves of each valve size and profile (Figure 3). The profiles achieve a desirable range of flow control and inherent rangeability. The valves share the same platform as the original Apollo full-port and standard-port valves, but are offered in 30-, 60-, and 90-degree Vs for equal percentage flow control, and a slotted version for narrow-band linear flow control (Figure 4).
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4. There are four ball options for control valves: 90-degree (-V9), 60-degree (-V6), and 30-degree (-V3) port options, or a 1/16-inch slot (-SX). Courtesy: Aalberts IPS |
For the power generation sector, the v-port series reportedly excels in applications such as deionized water polishing, boiler feedwater, and condensate polishing. The valves enhance system efficiency and reduce maintenance requirements, ensuring uninterrupted long-term operation, according to Aalberts IPS.
Maintenance Remains a Priority
Despite their essential roles, pumps, valves, and piping systems often receive attention only when problems arise. Yet, the consequences of failures in these components can be severe—ranging from reduced generation capacity and efficiency losses to catastrophic equipment damage and unplanned outages costing millions in repairs and lost revenue. In competitive energy markets, such disruptions can significantly impact both operational economics and a facility’s ability to meet grid demands.
Preventive maintenance strategies for these vital systems represent not merely an operational necessity but a strategic investment. As power plants face increasing pressure to extend service life while maintaining reliability, effective pump, valve, and piping management programs become differentiating factors in operational excellence. The most successful facilities have recognized that comprehensive maintenance approaches—incorporating condition monitoring, predictive analytics, and strategic component upgrades—yield substantial returns through improved efficiency, extended equipment life, and dramatically reduced downtime.
—Aaron Larson is POWER’s executive editor.
