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LIFE CYCLE COST Optimizing Pump Systems Dr. Gunnar Hovstadius Dir. Technology ITT FT. PRICE FUEL ECONOMY SAFETY DURABILITY. UTILITY MAINTENANCE INSURANCE PERFORMANCE RESELL VALUE. All of us use LCC. Energy & Maintenance costs LCC.

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LIFE CYCLE COST

Optimizing Pump Systems

Dr. Gunnar Hovstadius

Dir. Technology ITT FT


All of us use lcc

PRICE

FUEL ECONOMY

SAFETY

DURABILITY

UTILITY

MAINTENANCE

INSURANCE

PERFORMANCE

RESELL VALUE

All of us use LCC


Energy maintenance costs lcc
Energy & Maintenance costs LCC

  • 70% of energy production in industrialised countries drive electric motors

  • 70% of electric motors drive pumps, compressors and fans

  • Pumped systems account for 20% of the world’s electric energy demands

  • Energy and maintenance costs during the life of a pump system are usually more than10 times its purchase price


Pump lcc the product of and a spirit of global cooperation
PumpLCC, the product of … and a spirit of global cooperation

  • 1994 - U.S. DOE invited HI to participate in the Motor Challenge Program

  • 1995 - Flygt develops Sewage Lift station “DOE Energy Showcase” in CT

  • 1996 - Europump forms the Enersave committee

  • 1998 - HI and Europump form a joint committee to develop LCC guidelines

  • 2000 - Europump-HI “Pump Life CycleCosts-Global Best Practices” Guideline


Hydraulic institute europump
Hydraulic Institute - Europump

Life Cycle Cost (LCC) is the total lifetime

cost to purchase, install, maintain, and

dispose of that equipment. Costs:

  • Initial purchase

  • installation and commissioning

  • energy

  • operating

  • maintenance

  • downtime, loss of production

  • environmental cost

  • decommissioning


Cost components
Cost Components

  • Life Cycle Cost is the total lifetime cost to purchase, install, operate, maintain and dispose of that equipment.

    • HI/EP Oct. 2000

  • The purchase price is

    typically less than 15% of

    the total ownership cost.

  • Environmental

    7%


    Content
    CONTENT

    Chapter

    Executive Summary

    Introduction

    1 Life Cycle Cost

    2 Pumping System Design

    3 Analyzing Existing Pumping Systems

    4 Examples of LCC Analysis

    5 Effective Procurement using LCC

    6 Recommendations

    7 References

    8 Glossary

    9 Appendix A - E


    Appendixes
    APPENDIXES

    A System Curves

    B Pumping Output and System Control

    C Pump Efficiencies

    D Case History - Cost Savings

    E Electrical Drivers and Transmissions


    Manual calculation chart
    MANUAL CALCULATION CHART

    System description:

    Input:

    n - Life in years:

    i - Interest rate, %:

    p - Inflation rate %:

    - Initial investment cost:

    1

    - Installation and commissioning cost:

    2

    - Energy price (present) per kWh:

    - Weighted average power in kW:

    - Average Operating hours/year:

    Energy cost/year (calculated) = Energy price x

    3

    Weighted average power x Average Operating

    hours/

    yr

    - Operating cost/year:

    4

    - Average Maintenance cost (routine

    5

    maintenance/year):

    - Down time cost/year:

    6

    -Other yearly costs :

    7

    Sum of yearly costs

    -

    : (3+4+5+6+7)

    8



    Systems not pumps
    SYSTEMS, notpumps

    • LCC starts with the SYSTEM.

    • Replacing a 75% efficient pump with a 80% efficient pump will save almost 7% electricity cost

    • BUT … if pump systems are incorrectly sized, efficient pumps will operate at inefficient points

    • 75% of all engineered pump systems are estimated to be oversized.


    Pumps and system sizing energy to burn
    PUMPS and SYSTEM SIZINGEnergy to Burn

    • SYSTEM HEAD CALCULATIONS ARE CONSERVATIVE - SAFETY FACTORS

    • SINGLE PUMP, CONSTANT SPEED SYSTEMS SIZED FOR MAX DUTY

      • STATUTORY RULES IN MUNICIPAL

        WASTEWATER PUMPING

      • 40 DEG+ , THREE DAYS OF THE YEAR

    • SYSTEM COMPONENTS ARE OVER-

      SIZED - SAFETY FACTORS


    Pumps expensive water heaters
    Pumps: expensive water heaters

    • Pumps, over-sized for REAL system demands, lead to

      • frequent on / off cycling

      • closing of throttling valves

    • RESULT:

      • adding friction head to the system,

      • increasing Pump kW (electric power required)


    Energy
    ENERGY

    • Efficient pumps & efficient systems =>

      Specific Energy ( Wh/l pumped fluid )

      Calculate specific energy for the system and compare different solutions and different components


    Maintenance
    Maintenance

    • Throttled / oversized pumps run outside BEP

      • operate less efficiently,

      • generate radial loads & wear faster

        ….whereas

    • Accurately sized pumps and systems

      • reduce maintenance costs

      • increase seal, bearing, shaft life

      • increase MTBF

      • decrease labor maintenance

      • reduce production loss

      • reduce our warranty goodwill costs


    Lcc comparison example
    LCCComparison - Example

    10 Year Pump Life: : 80% eff60% eff

    800 gpm @ 90 ft BHP 16.95 kw22.60 kw

    • Pump / Motor Price $ 2,500 2,500

      ( with 30 hp motor)

    • Installation 500 500

    • Energy Costs* 33,900 45,200

      $ 0.05/ KwHr x 4000 hrs/yr x 10 yrs

    • Maintenance

      Parts (seals, bearings, shaft, impeller) - 4,000 8,000

      Labor 5 hrs/10hrs 2,000 4,000

    • Downtime - BI insurance pro-rate 1,200 1,200

    • Environmental ($ 150 x 2/yr and 3/yr) 3,000 4,500

    • Decommission650 650

      TOTAL LCC Comparison $ 47,550 $66,550

      Operating Savings $ 19,000


    Life cycle cost customer economic value
    LIFE CYCLE COSTCustomer Economic value

    • Reducing costs increases competitiveness

      • US Dept. Of Energy estimates 75-122 B KwH per year can be saved by “optimizing” motor driven pump systems

      • Savings would be between $ 4-6 B per year

    • Increase public services without raising public taxes and fees

      • Responding to the demands of private operators of public services to find system savings


    Life cycle cost environmental value
    LIFE CYCLE COSTEnvironmental Value

    Global commitment to environmental solutions -

    • Rio: Reduce ozone threatening emissions

    • Kyoto - commitment to reduce energy

    • 1 KwHr of electricity produces 600 grams of CO2. Saving 75-122B KwH will reduce 45 to 75 Billion Kg in CO2


    Putting lcc to work
    PUTTING LCC TO WORK

    • Think systems, not components.

    • Education of

      System owners, designers, specifiers, purchasers and producers

    • Concentrate on system performance, rather than component performance

    • Develop system specifications


    Life cycle cost
    LIFE CYCLE COST

    • ITT Industries EMBRACES LCC AS A TOOL FOR SELECTING AN OPTIMAL SOLUTION TO CREATE ECONOMIC AND ENVIRONMENTAL VALUE OVERTHE LIFE OF A SYSTEM


    New lcc focused products systems from itt industries
    New LCC Focused products/systems from ITT Industries

    • PumpSmart - advanced electronics and algorithms monitor system demands and varies the speed of the unit or shuts it down to protect the pump

    • Hydrovar Contol System - converts the pump from a constant speed to a variable speed unit

    • N-Pump - revolutionary impeller reduces the energy consumption by 30-50%

    • Sanitaire - a fine bubble aeration system that cuts energy costs by up to 50%


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