Economics Of System Optimization Colfax

Economic Benefits Achieved Through Fluid System Optimization

An Open Discussion

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Cost of operation savings through System Optimization

What if?

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What Matters?

– It’s not...Just the pump,

– Nor the individual components

It is…– A properly designed integral system,

– And the operation of the same

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That results in an “Optimized System”…

– Which Provides for:– Efficient Operation

– Reduced Maintenance

– Enhanced Reliability

– Increased Uptime and Availability

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Delivering to the end user?

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And for the rest of us….

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Positive Displacement Screw Pumps

The worlds shortest pump training session..

Really the worlds shortest…

Honest!!

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Imo 3 Screw Pump

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Double Ended Pump

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Geared Twin Screw Pump

INLET OUTLET

TIMING GEARS

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Ok, Who are these Colfax Guys anyway??

Well, were not just Imo Pumps any More….

That is assured!Global scope10 Separate business units15 Manufacturing locations30+ Strategic PartnersWe’ll talk a bit more later on…

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Application #1

Energy savings by means of “optimizing” the system to allow for proper operation.

The issue: An operational system that has optimal pump and system efficiency at 100% turbine load. However the system efficiency is compromised at normal operating levels of 70% load.

Project main Fuel Injection pumps feeding a 110Mw Simple Cycle Peaker

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The Project;

HECO (Hawaiian Electric Co.) at the Campbell Industrial Park generating station on the island of Oahu.

The prime mover at this 110-MW simple cycle power plant is a U.S. manufactured combustion turbine.

The plant is designed to operate with B100 BioDiesel renewable fuel as its primary fuel supply, a unique feature in today’s marketplace.

Clean distillate fuel will also be used for system flush prior to shutdown and will be contained in the system during extended shutdown periods.

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Bypass flow return to source

Fuel inlet

Imo AK12DHZ-275E

Flow D

ivider

Fuel flow to turbine com

bustors

Pump Output Full Flow and Pressure

Control Bypass Valve

Controlled Flow Rate Dependant Upon the Power Output Loads

Inlet Filtration

250HP, 3585 RPM

Premium Efficiency

IEEE-841 Motor

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Output at 100% load, 1500 psi

Distillate B100

Pump RPM 3585 3585

Viscosity 1.8 cSt 10 cSt

Delivered Flow (GPM) 203 214

BHP Required 234 234

Typical flow to turbine for 100% load

180 180

By Pass Flow 22 34

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Output at 70% load, 1000 psi

Distillate BioDiesel

Pump RPM 3585 Full Motor Speed

Delivered Flow (GPM) 211 216


Typical Flow to turbine for 70% Load 135 135

By Pass Flow 76 81

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This type of operation is prevalent in nearly all combustion turbine installations built by US based manufactures.

Well, we now do know that this type of system can easily be “Optimized” by the addition of some Colfax “Smart System Controls”!

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Bypass flow returned to source

Fuel inlet

250HP, 3585 RPM

Premium EfficiencyIEEE-841 Motor

Imo AK12DHZ-275E

Flow D

ivider

Fuel flow to turbine com

bustors

Pump Output Full Flow and Pressure

Control Bypass Valve

Controlled Flow Rate Dependant Upon the Power Output Loads

Colfax “Smart System”

ControlsInlet Filtration

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Pump Output at Controlled operational speeds

Distillate BioDiesel

Pump RPM 2600 Controlled Motor Speed

Delivered Flow 144 148


Typical Flow to turbine for 70% Load

135 135

By Pass Flow 9 GPM 13 GPM

By Pass Flow Differential 67 GPM-86% 68 GPM-81%

Horsepower Saved 49 49

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Hawaiian electric rates are $.299 / Kw/HrHorsepower saved 49Equivalent kilowatts 35What are the savings?1 hour = $10.991 day = $263.721 year = $96,257.00

5 year = $481,285.00

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Consider that:

Without considering inflation and fuel costs in the future the energy saved in the operation of this fairly small combustion turbine will be nearly $2,500,000.00 over the 25 year life expectancy of the plant!

And this operational scheme will work on:

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Boiler Fuel Injection Pumps in Steam Turbines.

Fuel Transfer and Forwarding.

Boiler Feed and Condensate Pumps.

Any system that has a variable system flow or pressure demand is a candidate for this type of upgrade…

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Another example

A large New England Steam Turbine Plant which operates primarily on residual fuel.

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Savings

$ / MW-hr 0.065 0.15 0.20 0.25

Savings Per Year $60,191.04 $138,902.40 $185,203.20 $231,504.00

Savings Over 5 years $300,955.20 $694,512.00 $926,016.00 $1,157,520.00

Savings over 25 years $1,504,776.00 $3,472,560.00 $4,630,080.00 $5,787,600.00

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Application #2– Savings gained by considering other options in equipment selection in

lieu of the “Usual Type” of equipment previously utilized.– Then when using TCO comparisons in the design stage the overall

economic benefits will be clearly evident

Project: – Pipe line, Fuel Transfer, and Unloading systems

Solution:– The use of Positive Displacement pumps in lieu of the “Obvious

Choice” Centrifugal machines.

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Let’s look at a pipeline application where the operational conditions would normally call out for a multi-stage centrifugal pump….

This application is for a 4380GPM pipeline delivering a light crude oil…

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In the Oil and Gas Industry there still remains a preference for the use of centrifugal pumps (even when horribly misapplied) because….

”We can always fix them in our shops”

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How about a pump that doesn’t break down?

Or, “Yes you can do an on-site repair quick and cheap”

But do you know how much it really costs to operate the equipment?

Despite the initial capital equipment costs and 5 years of parts and maintenance charges being nearly equal….

The total “Savings Gained” are:

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TCO Breakdown for PD Pumps at 300 cP

19%

20%61%

TCO Breakdown for Centrif Pumps at 300 cP13%

11%

76%

Energy Costs for 5 Years "per Pump" @ 10 cents US per kW/hr: Crude oil at 300 cP $1,166,490.36 Crude oil at 300 cP $578,343.96TCO for crude oil at 300 cP $6,156,199.74 TCO for crude oil at 300 cP $4,355,990.55

•The cost of Energy saved is $1,800,209.00 over 5 years

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Application #3

– Savings by means of utilizing “Optimally Designed” equipment.

Project:

– Main Lube and Seal Oil Pump for GE Frame 7-FA/FB Gas Turbines

Solution:

– The application of pump sets that were specifically designed for this type of “Mission Critical” service

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The Problems

Excessive Maintenance Costs.Short Maintenance IntervalsMany Field FailuresUnresponsive SupplierOEM Turbine Manufacturer does not consider the operators cost of operation.

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The Solution:To Incorporate a pump that had been from the onset, specifically designed, for “Mission Critical Application” service.

Providing:Robust designVery High ReliabilityLow maintenance requirementsExtended service intervals to coincide with planned outages.

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On average the cost of maintenance of the original design pumps is from $15,000.00 to $17,000.00 per year per turbine…

A Combined Cycle installation of 2 two Combustion Turbines and one Steam Turbine can cost around $40- $45 K per year

The Savings gained by doing it right are:

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Colfax Buffalo

372A5012 Main and Auxiliary Lube Oil Pump 9FA 50Hz CTBHP Kw $ / hr $ / Yr $ / 25 Yr BHP Kw $ / hr $ / Yr $ / 25 Yr108 80.57 $9.77 $85,575.30 $2,139,382.53 113 84.30 $10.54 $92,306.31 $2,307,657.7563% 60

1050 GPM303 ft

Maintenance Major Maintenance Event Major Maintenance EventInspect / Replace Main Bearing 6 bearing service events and 1 Major serviceService interval 5.7 years Service interval 1yearCost per interval $5,000.00 Cost per interval $13,000.00Cost Over 25 years $15,000.00 Cost Over 25 years $325,000.00

Cost of at least one failure $20,000.00TCO Colfax $2,159,382.53 TCO Buffalo $2,652,657.75incl. Energie costs incl. Energie costsexcl. Purchase price excl. Purchase price

Differential $493,275.22

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The Common Thread?

An economic analysis along with component or system design…

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So who is Colfax?

We are:

A world leader in the development, engineering, manufacturing, distribution, service and support of pumping and fluid-handling systems…

A synergistic group of individual pump, systems, instrumentation manufactures, and “Strategic Partners”…

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The world’s largest Positive Displacement Pump Manufacturer.

The 6th largest pump / fluid system manufacturer…

Global…15 manufacturing locations

Strategically located Service and Applications engineering personnel…

Our reach is Global, your contacts are local…

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9 individual pump manufacturing business units

Specialized Instrumentation and Controls group

We have access to nearly every pump technology!

Skid and System design and construction expertise In US and international specifications…

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Our Brands

http://www.allweiler.de/

http://www.portlandvalve.com/

http://www.fairmountautomation.com/

http://www.houttuin.nl/

http://www.tushacopumps.com/

http://www.imo.se/

http://www.imo.se/

http://www.warrenpumps.com/

http://www.zenithpumps.com/

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Your pump and fluid systems design and equipment selection expertise has grown exponentially…..

No charge for opinions…

Here’s some interesting pictures…

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Thank You!!!!

Date post:	05-Dec-2014
Category:	Education
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Economics Of System Optimization Colfax

Education