Overcoming Challenges at P66 Sweeny, TX Refinery
The P66 Sweeny Refinery in Southeast Texas recently faced a significant challenge due to consistent drought conditions over the past several years. This situation forced the refinery to reevaluate and replace its three existing river water pumps, which were originally installed in 1956. These pumps, two-stage mixed flow verticals built by Fairbanks Morse, had become unreliable, and their performance significantly declined due to continuous rebuilds.
The Water Shortage Challenge
In the refining process, it requires two gallons of water to refine one gallon of crude oil. With the ongoing drought and increased production, P66 faced a water shortage, making efficient water pump operation critical. Given capital constraints, the new pumps needed to operate with the original 1956 300 HP motors, as upgrading the electrical infrastructure was deemed too costly.
Original Application Details
- Total Pump Length: 40 ft.
- Head: Below Grade
- Motor: Original 300 HP
- Speed: 600 RPM
- Original Flow: 22,400 GPM
- TDH: 48 ft.
- Liquid: River Water
Seeking Solutions
P66 approached DXP for a solution. Our team of experts knew what needed to be done and faced the challenge head-on, but we knew it would be a challenge to find a major pump brand that would take on this job with the horsepower requirements at the given flow rate. We approached four major pump companies and one after the other declined to bid on the project due to the challenging horsepower and flow rate combination. Finally, Xylem’s Large Bowl Turbine (LBT) group was considered for the task. A compromise was reached to decrease the flow to 21,000 GPM, keeping just below the 300-horsepower limit.
The Solution
Xylem provided a single-stage 36GL pump designed to work with the existing 1956 vertical motors. The details of the final solution are as follows:
- Flow: 21,000 GPM
- TDH: 48 ft.
- BHP: 296 HP
- Bowl: 36” Duplex Stainless Steel
- TPL: 40 ft.
The result is a pump with comparable flow, a smaller diameter, reliable service, and longevity that should see these pumps in service well into the future.
Despite the challenging conditions and constraints, DXP was able to implement a successful solution that ensures reliable water pump performance for the customer. This case demonstrates the importance of innovative thinking and collaboration in overcoming industrial challenges.
Learn More About DXP’s Custom Pump Solutions
At DXP, we thrive on solving complex industrial challenges with innovative and customized solutions. Our team of experts is dedicated to understanding your unique needs and delivering tailored equipment that enhances performance and reliability. From evaluating existing systems to designing and implementing new solutions, we are committed to ensuring your operations run smoothly and efficiently!
Contact us today to learn more about our pump solutions.