How to Cut Energy Usage by almost 50% on Legacy BB5 Installations with Re Rate Solutions
Many legacy high-head BB5 pumps continue to operate far from their original design point following plant or process modifications, resulting in significant energy waste and unnecessary CO₂ emissions. This paper presents two proven re-rate strategies for restoring pump efficiency: optimized de-staging and complete hydraulic bundle replacement using CFD-engineered flow paths and advanced non-metallic wear components. A case study on a 13-stage boiler feed pump demonstrates that operation under de-rated conditions can reduce system efficiency by up to 47%, primarily due to throttling losses. By implementing an optimized re-rate solution, substantial energy savings can be achieved while maintaining safe and reliable operation. The highest benefits are obtained through a fully redesigned hydraulic assembly, which eliminates unnecessary energy consumption, improves hydraulic performance, reduces CO₂ emissions, and extends asset life. The approach provides utilities and power producers with a practical pathway to improve energy efficiency and sustainability without replacing the entire pump installation.
Speaker(s)
Nehad Shawki holds a B.Sc. in Electrical Power Engineering from the Faculty of Engineering at Ain Shams University in Cairo, Egypt. He joined Trillium’s Italian pump business in 1999 and has spent more than 26 years contributing to the growth of both the OEM and aftermarket service businesses across international markets. During his career, he has held a range of sales and marketing leadership roles, helping strengthen customer relationships and expand business opportunities worldwide. He currently serves as Manager of Trillium’s Service Center in Abu Dhabi, where he oversees service operations and supports customers across the region.
