ENHANCING OIL PUMPING STATION EFFICIENCY THROUGH MODERNIZATION OF NM 3600/230 UNITS

Abstract. This article presents the results of the technical and economic analysis of the modernization of NM 3600/230 mainline pumping units at Pumping Station No.1 of the B. Dzhumagaliev Main Oil Pumping Station (MNPS). The proposed modernization involves replacing outdated synchronous electric drive systems with energy-efficient asynchronous motors and integrating automated control systems. The study demonstrates significant improvements in reliability, energy consumption, and maintenance costs, confirming the feasibility of the modernization project for application across similar facilities in the oil transportation industry.

Keywords: increase, efficiency, oil refinery.

1. Introduction

Reliable and energy-efficient operation of pumping equipment is crucial in long-distance oil pipeline infrastructure. The NM 3600/230 units at Pumping Station No.1 of the B. Dzhumagaliev MNPS have been in service for decades, and operational analysis revealed reduced efficiency, frequent failures, and high energy demands due to aging synchronous motors and supporting systems. This study focuses on assessing the current equipment's condition and justifying the transition to modern, cost-effective pumping solutions.

Figure 1. Pumping Station No.1 of the B. Dzhumagaliev

2. Object and Methods of Research

The object of the study is the NM 3600/230 mainline centrifugal pump equipped with a 2500 kW synchronous electric motor (STDП-2500), installed at the B. Dzhumagaliev MNPS. The modernization strategy includes replacement with the NM 1250/260 pump driven by an asynchronous 1250 kW motor (4AZMV 1250/1000 U2.5), installation of frequency converters, and elimination of auxiliary systems (cooling, excitation, etc.). Analysis was based on technical diagnostics, economic comparison of lifecycle costs, and energy audit results.

3. Results and Discussion

3.1 Technical Improvements

The replacement resulted in a simplified and more reliable configuration. The new asynchronous motors operate effectively with frequency converters, allowing flexible speed control and significant reduction in energy consumption. The total mass of the new unit is significantly lower (8040 kg vs. 15,730 kg), reducing load on foundations.

3.2 Automation and Control

The upgraded unit is integrated into an automated control and monitoring system using S800 I/O stations and Profibus DP communication. This enables real-time data acquisition, remote diagnostics, and enhanced operational safety.

3.3 Economic Benefits

The modernization led to the elimination of auxiliary systems such as excitation devices (CRVD), forced ventilation, and oil cooling, resulting in considerable cost savings:

• Annual energy savings: over 5 million KZT per station.
• Reduction in maintenance labor costs: up to 384 person-hours annually per station.
• CRVD maintenance cost savings: 17.1 million KZT annually across 8 replaced motors.

Additionally, five incidents linked to the old synchronous systems were avoided after the upgrade, improving operational reliability.

4. Conclusion

The modernization of NM 3600/230 pumping units with the implementation of NM 1250/260 units powered by asynchronous motors demonstrated measurable benefits. These include:

• Enhanced energy efficiency and reduced power demand;
• Simplified maintenance and increased operational uptime;
• High adaptability to automated control and monitoring systems.

The proposed approach is technically and economically justified and can be replicated at similar facilities within the oil pipeline infrastructure of Kazakhstan and beyond.