PLANTSERV® Lifetime Extension in Conjunction with Energy Transition
Special edition: Discover our solution in practice and see how you too can unlock new business opportunities.
Our seamless, comprehensive service portfolio takes the complexity out of challenging projects balancing revamps with machine electrification.
With a focus on emissions abatement, governments are tightening regulations all over the world. For plant owners and operators, revamps are a good opportunity to decarbonize their assets and ready them for the future. Yet revamps are often quite complex, with a favorable outcome depending to a large extent on careful planning, engineering excellence and expert project management.
Many such projects focus on changing the energy source for ASU compressors from steam to electricity.
“Generally speaking, steam to electricity is very complicated revamp work, though an extremely effective way to decarbonize,” says
Guoping Yang, Head of PLANTSERV® APAC.
“Generally speaking, steam to electricity is very complicated revamp work, though an extremely effective way to decarbonize,” says
Guoping Yang, Head of PLANTSERV® APAC.
Lifetime Extension in Practice
Modernize your plant for added value, extend service life or even relocate your asset with our holistic lifetime solutions. Our expert team is dedicated to finding solutions for your unique requirements – from minor modifications to complex, full-scale projects requiring utmost precision and quality. For younger plants, we develop revamp concepts to enable growth, meet increased customer demand or adapt to specific new market or legislative requirements.
Our PLANTSERV® engineers start with a detailed investigation of your process plant to assess the viability and potential savings of a revamp. Factors such as market demand, plant design, site conditions, operability and cost-effectiveness are taken into consideration. This is followed by a feasibility study to define the best solution, balancing constraints such as shutdown windows, constructability, budget, OPEX and other operational requirements.
In a recent project, the customer was keen to maximize the use of existing infrastructure and equipment, which was in the middle of its useful life. Our team grasped the opportunity to also exchange the compressors, thus increasing efficiency and extending lifetime, and to substitute steam turbines with electric machinery. All of this was executed on existing the platform to minimize civil works and construction effort.
Our PLANTSERV® engineers start with a detailed investigation of your process plant to assess the viability and potential savings of a revamp. Factors such as market demand, plant design, site conditions, operability and cost-effectiveness are taken into consideration. This is followed by a feasibility study to define the best solution, balancing constraints such as shutdown windows, constructability, budget, OPEX and other operational requirements.
In a recent project, the customer was keen to maximize the use of existing infrastructure and equipment, which was in the middle of its useful life. Our team grasped the opportunity to also exchange the compressors, thus increasing efficiency and extending lifetime, and to substitute steam turbines with electric machinery. All of this was executed on existing the platform to minimize civil works and construction effort.
Emissions Reduction in Practice
Our commitment to a more sustainable future for industrial plants is reflected in our innovative portfolio. With a comprehensive offering aimed at decarbonization and emissions reduction, we are well-equipped to support your sustainability goals. Our offering extends from sustainability studies through water efficiency and waste minimization audits to full-scale net-zero roadmaps – all geared towards economically meeting your emissions reduction targets.
Successful references showcase the potential of machine electrification in unlocking new business opportunities by drastically improving the carbon footprint of industrial plants.
Looking at a typical electrification project, the booster air compressor (BAC) and the main air compressor (MAC) had reached the end of their lifecycle, and our engineers were tasked with integrating new equipment. Continuity of gas supply was crucial for the downstream customer, which is why the work was split into several, short shutdown windows. Our team installed the new BAC and MAC units, electrical machinery and piping beside the existing ones during live operations, and carried out the actual replacement work during the shutdowns. The entire substation was pre-assembled and tested to plug-and-play level. Careful planning was key, and the construction sequence was precisely planned to ensure the work could be carried out safely while maintaining the tight schedules.
The new BAC, MAC and electrical machines were successfully integrated on both ASU trains during three shutdown windows. Successful project outcomes include maximum leverage of the existing facilities and added operational value thanks to an increase in capacity for high-pressure gaseous oxygen (GOX) and clean dry air (CDA).
Successful references showcase the potential of machine electrification in unlocking new business opportunities by drastically improving the carbon footprint of industrial plants.
Looking at a typical electrification project, the booster air compressor (BAC) and the main air compressor (MAC) had reached the end of their lifecycle, and our engineers were tasked with integrating new equipment. Continuity of gas supply was crucial for the downstream customer, which is why the work was split into several, short shutdown windows. Our team installed the new BAC and MAC units, electrical machinery and piping beside the existing ones during live operations, and carried out the actual replacement work during the shutdowns. The entire substation was pre-assembled and tested to plug-and-play level. Careful planning was key, and the construction sequence was precisely planned to ensure the work could be carried out safely while maintaining the tight schedules.
The new BAC, MAC and electrical machines were successfully integrated on both ASU trains during three shutdown windows. Successful project outcomes include maximum leverage of the existing facilities and added operational value thanks to an increase in capacity for high-pressure gaseous oxygen (GOX) and clean dry air (CDA).
Machine Electrification in ASUs
What’s the best electrification strategy for your ASU?
The answer to this question is often more complex than you might think. While adding electrical machinery to an existing plant might seem easy at first glance, there are many factors to consider to ensure an ideal fit and efficient operations.
The answer to this question is often more complex than you might think. While adding electrical machinery to an existing plant might seem easy at first glance, there are many factors to consider to ensure an ideal fit and efficient operations.
The deployment options in brownfield environments hinge on the situation on site, including the existing layout, foundations and power grid connection.
Other core factors in the electrification decision-making process include:
- the number of machines deployed
- the type of gears
- whether you use one or more variable frequency drives (VFDs)
These and other factors must be carefully weighed up to reflect your individual ASUs requirements. After all, the best revamp option is always the one that achieves the desired outcome with the lowest effort and cost. Our experts have the experience to help you strike the perfect balance.
Savings in Focus
Other core factors in the electrification decision-making process include:
- the number of machines deployed
- the type of gears
- whether you use one or more variable frequency drives (VFDs)
These and other factors must be carefully weighed up to reflect your individual ASUs requirements. After all, the best revamp option is always the one that achieves the desired outcome with the lowest effort and cost. Our experts have the experience to help you strike the perfect balance.
Savings in Focus
- Machine electrification: Choosing the right set-up and integration method leads to faster return on investment along with CAPEX & OPEX savings
- Preparation works: Detailed preparation reduces downtime and accelerates execution
- Operating cost: $1.4 m potential OPEX savings per year estimated for a 65,000 standard cubic meters per hour (Nm3/h) plant through electrification
ALL-IN-ONE: Lifetime Extension and Energy Transition
Do you know how to best convert your compressor drives from steam to electricity while also resolving other, more complex operational challenges?
WE DO!
Discover how our solutions have already unlocked new business opportunities for our customers.
Below you can read about the key drivers behind game-changing reference projects and explore how our innovative technologies were successfully deployed to achieve incredible results.
Below you can read about the key drivers behind game-changing reference projects and explore how our innovative technologies were successfully deployed to achieve incredible results.
Our PLANTSERV® team drove the conversion of motors from steam to electricity at four air separation units in China, thus reducing carbon emission by around half a million tons per year.
The key drivers, solution and results are summarized below:
The key drivers, solution and results are summarized below:
Key drivers
- Reduction of steam (generated from coal) consumed by plant and improvement of steam balance by reducing carbon
- Leverage of existing ASU equipment with efficiency gains
- Use of low-carbon green power to drive electric motors
Our solution
- Engineering, procurement & construction
- Revamp of existing MAC and BAC
- Integration of electric motors for MAC (29 MW) & BAC (11 MW)
- MV/LV electrical system incl. new transformers and switchgears
- Revamp of lube oil system
- Innovative solution by placing MAC and BAC on same (revamped) platform
Ultimate results
- By converting from steam to electricity, the client reduced carbon emissions by ~40% (corresponding to approx. 250,000 tons/year)
- Revamped BAC eliminated need for variable frequency drive, which improved operational reliability
- Maximum utilization of existing equipment, minimal CAPEX for new equipment
Big Carbon Emission Savings
Converting ASUs is a big step on the carbon reduction journey. By converting from steam to electricity,
“Wanhua and Linde Gas have been able to reduce carbon dioxide equivalent emissions by approximately 500,000 tons per year. Moreover, the ASUs are more reliable, providing an even better service for a major gas customer. It’s a win-win all around – thanks to the experience and expertise of the PLANTSERV® team,” says
Lu Rong, Head of Business Development RGC.
“Wanhua and Linde Gas have been able to reduce carbon dioxide equivalent emissions by approximately 500,000 tons per year. Moreover, the ASUs are more reliable, providing an even better service for a major gas customer. It’s a win-win all around – thanks to the experience and expertise of the PLANTSERV® team,” says
Lu Rong, Head of Business Development RGC.
Combining lifetime extensions with emissions reductions is no easy feat,
and only a market leader can deliver a comprehensive solution that achieves both simultaneously.
Trust in our expertise and experience, and let us help you extend the lifetime of your industrial plant while reducing emissions and improving your bottom line.
Trusted Provider of Lifecycle Solutionss
Linde PLANTSERV® is a trusted industry leader for aftersales asset management.
We are deeply committed to improving the reliability and efficiency of industrial process plants in a safe, innovative and sustainable way.
Our services combine the best technologies with the best people to deliver integrated and customized solutions that extend along your entire asset lifecycle.
Our PLANTSERV® lifecycle portfolio ranges from design through execution to operations
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